High Melt Flow Polypropylene Homopolymers for Fiber Applications

ABSTRACT

Disclosed herein are high melt flow polypropylene homopolymers generally characterized by a melt flow rate ranging from 200 g/10 min to 3000 g/10 min, a ratio of Mw/Mn ranging from 2 to 5, and a peak melting point ranging from 138° C. to 151° C. These polypropylene homopolymers can be produced by catalyst systems containing a racemic ansa-bis(indenyl)zirconocene compound, an activator-support, and an organoaluminum co-catalyst.

FIELD OF THE INVENTION

The present disclosure concerns catalyst systems containing a bridgedbis(indenyl) metallocene compound and an activator-support, and moreparticularly relates to the use of such catalyst systems to produce highmelt flow polypropylene homopolymers.

BACKGROUND OF THE INVENTION

Polyolefins such as polypropylene homopolymers can be produced usingvarious combinations of catalyst systems and polymerization processes.However, the production of high melt flow polypropylene homopolymersoften requires the use of vis-breaking techniques and peroxide additivesto reduce the viscosity and to increase the melt flow rate. It would bebeneficial to produce the high melt flow rate polypropylene homopolymerswithout the need for the vis-breaking techniques and peroxide additives.Moreover, it would be beneficial to produce these high melt flow ratepolypropylene homopolymers with molecular weight and melting pointcharacteristics that make them particularly suitable for use in fiberand related end-use applications. Accordingly, it is to these ends thatthe present disclosure is directed.

SUMMARY OF THE INVENTION

The present invention generally relates to polypropylene homopolymerscharacterized by a melt flow rate in a range from about 200 g/10 min toabout 3000 g/10 min, a ratio of Mw/Mn in a range from about 2 to about5, and a peak melting point in a range from about 138° C. to about 151°C. In some embodiments, the polypropylene homopolymer can have a meltflow rate in a range from about 200 g/10 min to about 3000 g/10 min, aratio of Mw/Mn in a range from about 2 to about 5, and a ratio of Mz/Mwin a range from about 1.7 to about 3.5. Beneficially, thesepolypropylene homopolymers can be produced in a single reactor, andwithout the need for a vis-breaking step and related peroxide additives.These polypropylene homopolymers can be used to produce various articlesof manufacture, such as molded products, nonwoven articles, and fibersor fabrics.

Catalyst compositions and polymerization processes used to produce thepolypropylene homopolymers also are disclosed herein. For instance, acatalyst composition of this invention can comprise a racemicansa-bis(indenyl)zirconocene compound, an activator-support, and anoptional co-catalyst. An illustrative polymerization process cancomprise contacting the catalyst composition (i.e., any catalystcomposition disclosed herein) with propylene in a polymerization reactorsystem under polymerization conditions to produce the polypropylenehomopolymer.

Both the foregoing summary and the following detailed descriptionprovide examples and are explanatory only. Accordingly, the foregoingsummary and the following detailed description should not be consideredto be restrictive. Further, features or variations may be provided inaddition to those set forth herein. For example, certain aspects andembodiments may be directed to various feature combinations andsub-combinations described in the detailed description.

BRIEF DESCRIPTION OF THE FIGURES

The following figures form part of the present specification and areincluded to further demonstrate certain aspects of the presentinvention. The invention may be better understood by reference to one ormore of these figures in combination with the detailed description ofspecific embodiments presented herein.

FIG. 1 presents a plot of a calibration curve for the determination ofthe polypropylene melt flow rate based on the viscosity at 230° C. inPa-sec.

FIG. 2 presents a plot of catalyst productivity for metallocenecompounds B, C, and D based on the amount of hydrogen present duringpolymerization.

FIG. 3 presents a plot of the melt flow rates of polypropylenes producedusing metallocene compounds B, C, or D based on the amount of hydrogenpresent during polymerization.

FIG. 4 presents a plot of the molecular weight distributions (MWDs,ratios of Mw/Mn) of polypropylenes produced using metallocene compoundsB, C, or D based on the amount of hydrogen present duringpolymerization.

DEFINITIONS

To define more clearly the terms used herein, the following definitionsare provided. Unless otherwise indicated, the following definitions areapplicable to this disclosure. If a term is used in this disclosure butis not specifically defined herein, the definition from the IUPACCompendium of Chemical Terminology, 2nd Ed (1997), can be applied, aslong as that definition does not conflict with any other disclosure ordefinition applied herein, or render indefinite or non-enabled any claimto which that definition is applied. To the extent that any definitionor usage provided by any document incorporated herein by referenceconflicts with the definition or usage provided herein, the definitionor usage provided herein controls.

While compositions and methods are described herein in terms of“comprising” various components or steps, the compositions and methodscan also “consist essentially of” or “consist of” the various componentsor steps, unless stated otherwise. For example, a catalyst compositionconsistent with the present invention can comprise; alternatively, canconsist essentially of; or alternatively, can consist of; a metallocenecompound, an activator-support, and optionally, a co-catalyst.

The terms “a,” “an,” and “the” are intended to include pluralalternatives, e.g., at least one, unless otherwise specified. Forinstance, the disclosure of “an activator-support” or “a metallocenecompound” is meant to encompass one, or mixtures or combinations of morethan one, activator-support or metallocene compound, respectively,unless otherwise specified.

Generally, groups of elements are indicated using the numbering schemeindicated in the version of the periodic table of elements published inChemical and Engineering News, 63(5), 27, 1985. In some instances, agroup of elements can be indicated using a common name assigned to thegroup; for example, alkali metals for Group 1 elements, alkaline earthmetals for Group 2 elements, transition metals for Group 3-12 elements,and halogens or halides for Group 17 elements.

For any particular compound disclosed herein, the structure or namepresented is intended to encompass all structural isomers,conformational isomers, and stereoisomers that can arise from aparticular set of substituents, unless stated otherwise. Also, unlessstated otherwise, the structure or name also encompasses allenantiomers, diastereomers, and other optical isomers whether inenantiomeric or racemic forms, as well as mixtures of stereoisomers, aswould be recognized by a skilled artisan. Thus, unless indicatedotherwise, a general reference to pentane includes n-pentane,2-methyl-butane, and 2,2-dimethylpropane, while a general reference to abutyl group includes an n-butyl group, a sec-butyl group, an iso-butylgroup, and a tert-butyl group.

The term “substituted” when used to describe a group, for example, whenreferring to a substituted analog of a particular group, is intended todescribe any non-hydrogen moiety that formally replaces a hydrogen atomin that group, and is intended to be non-limiting. A group or groups canalso be referred to herein as “unsubstituted” or by equivalent termssuch as “non-substituted,” which refers to the original group in which anon-hydrogen moiety does not replace a hydrogen atom within that group.Unless otherwise specified, “substituted” is intended to be non-limitingand include inorganic substituents or organic substituents as understoodby one of ordinary skill in the art.

The term “hydrocarbon” whenever used in this specification and claimsrefers to a compound containing only carbon and hydrogen. Otheridentifiers can be utilized to indicate the presence of particulargroups in the hydrocarbon (e.g., halogenated hydrocarbon indicates thepresence of one or more halogen atoms replacing an equivalent number ofhydrogen atoms in the hydrocarbon). The term “hydrocarbyl group” is usedherein in accordance with the definition specified by IUPAC: a univalentgroup formed by removing a hydrogen atom from a hydrocarbon (that is, agroup containing only carbon and hydrogen). Non-limiting examples ofhydrocarbyl groups include alkyl, alkenyl, aryl, and aralkyl groups,amongst other groups.

The term “polymer” is used herein generically to include olefinhomopolymers, copolymers, terpolymers, and the like, as well as alloysand blends thereof. The term “polymer” also includes impact, block,graft, random, and alternating copolymers. A copolymer is derived froman olefin monomer and one olefin comonomer, while a terpolymer isderived from an olefin monomer and two olefin comonomers. Accordingly,“polymer” encompasses copolymers and terpolymers derived from any olefinmonomer and comonomer(s) disclosed herein. Thus, a propylene polymerwould include polypropylene homopolymers, propylene-based copolymers,propylene-based terpolymers, and the like. Similarly, the scope of theterm “polymerization” includes homopolymerization, copolymerization, andterpolymerization. The term “polymer” also includes all possiblegeometrical configurations, unless stated otherwise, and suchconfigurations may include isotactic, syndiotactic, and randomsymmetries.

The term “co-catalyst” is used generally herein to refer to compoundssuch as aluminoxane compounds, organoboron or organoborate compounds,ionizing ionic compounds, organoaluminum compounds, organozinccompounds, organomagnesium compounds, organolithium compounds, and thelike, that can constitute one component of a catalyst composition, whenused, for example, in addition to an activator-support. The term“co-catalyst” is used regardless of the actual function of the compoundor any chemical mechanism by which the compound may operate.

The term “activator-support” is used herein to indicate a solid,inorganic oxide of relatively high porosity, which can exhibit Lewisacidic or Brønsted acidic behavior, and which has been treated with anelectron-withdrawing component, typically an anion, and which iscalcined. The electron-withdrawing component is typically anelectron-withdrawing anion source compound. Thus, the activator-supportcan comprise a calcined contact product of at least one solid oxide withat least one electron-withdrawing anion source compound. The terms“support” and “activator-support” are not used to imply these componentsare inert, and such components should not be construed as an inertcomponent of the catalyst composition. The term “activator,” as usedherein, refers generally to a substance that is capable of converting ametallocene component into a catalyst that can polymerize olefins, orconverting a contact product of a metallocene component and a componentthat provides an activatable ligand (e.g., an alkyl, a hydride) to themetallocene, when the metallocene compound does not already comprisesuch a ligand, into a catalyst that can polymerize olefins. This term isused regardless of the actual activating mechanism. Illustrativeactivators include activator-supports, aluminoxanes, organoboron ororganoborate compounds, ionizing ionic compounds, and the like.Aluminoxanes, organoboron or organoborate compounds, and ionizing ioniccompounds generally are referred to as activators if used in a catalystcomposition in which an activator-support is not present. If thecatalyst composition contains an activator-support, then thealuminoxane, organoboron or organoborate, and ionizing ionic materialsare typically referred to as co-catalysts.

The term “metallocene” as used herein describes compounds comprising atleast one η³ to η⁵-cycloalkadienyl-type moiety, wherein η³ toη⁵-cycloalkadienyl moieties include cyclopentadienyl ligands, indenylligands, fluorenyl ligands, and the like, including partially saturatedor substituted derivatives or analogs of any of these. Possiblesubstituents on these ligands may include H, therefore this inventioncomprises ligands such as tetrahydroindenyl, tetrahydrofluorenyl,octahydrofluorenyl, partially saturated indenyl, partially saturatedfluorenyl, substituted partially saturated indenyl, substitutedpartially saturated fluorenyl, and the like. In some contexts, themetallocene is referred to simply as the “catalyst,” in much the sameway the term “co-catalyst” is used herein to refer to, for example, anorganoaluminum compound.

The terms “catalyst composition,” “catalyst mixture,” “catalyst system,”and the like, do not depend upon the actual product or compositionresulting from the contact or reaction of the initial components of thedisclosed or claimed catalyst composition/mixture/system, the nature ofthe active catalytic site, or the fate of the co-catalyst, themetallocene compound, or the activator-support, after combining thesecomponents. Therefore, the terms “catalyst composition,” “catalystmixture,” “catalyst system,” and the like, encompass the initialstarting components of the composition, as well as whatever product(s)may result from contacting these initial starting components, and thisis inclusive of both heterogeneous and homogenous catalyst systems orcompositions. The terms “catalyst composition,” “catalyst mixture,”“catalyst system,” and the like, may be used interchangeably throughoutthis disclosure.

The term “contact product” is used herein to describe methods andcompositions wherein the components are combined or contacted togetherin any order, in any manner, and for any length of time, unlessotherwise specified. For example, the components can be contacted byblending or mixing. Further, unless otherwise specified, the contactingof any component can occur in the presence or absence of any othercomponent of the methods and compositions described herein. Combiningadditional materials or components can be done by any suitable method.This term encompass mixtures, blends, solutions, slurries, reactionproducts, and the like, as well as combinations thereof. Similarly, theterm “contacting” is used herein to refer to materials which can beblended, mixed, slurried, dissolved, reacted, treated, or otherwisecontacted in some other manner.

The terms Mn, Mw, and Mz, as used herein, are defined as follows: Mn:number-average molecular weight; Mw: weight-average molecular weight;and Mz: z-average molecular weight. These values are determined bycalculations on the basis of molecular weight distribution curvesdetermined using gel permeation chromatography (GPC), also known assize-exclusion chromatography (SEC). Unless otherwise specified herein,the terms “MWD” and “molecular weight distribution” refer to the ratioof Mw/Mn.

Although any methods, devices, and materials similar or equivalent tothose described herein can be used in the practice or testing of theinvention, the typical methods, devices, and materials are hereindescribed.

All publications and patents mentioned herein are incorporated herein byreference for the purpose of describing and disclosing, for example, theconstructs and methodologies that are described in the publications,which might be used in connection with the presently describedinvention.

Several types of ranges are disclosed in the present invention. When arange of any type is disclosed or claimed, the intent is to disclose orclaim individually each possible number that such a range couldreasonably encompass, including end points of the range as well as anysub-ranges and combinations of sub-ranges encompassed therein. Forexample, when a chemical moiety having a certain number of carbon atomsis disclosed or claimed, the intent is to disclose or claim individuallyevery possible number that such a range could encompass, consistent withthe disclosure herein. For example, the disclosure that a moiety is a C₁to C₁₈ hydrocarbyl group, or in alternative language, a hydrocarbylgroup having from 1 to 18 carbon atoms, as used herein, refers to amoiety that can have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,16, 17, or 18 carbon atoms, as well as any range between these twonumbers (for example, a C₁ to C₈ hydrocarbyl group), and also includingany combination of ranges between these two numbers (for example, a C₂to C₄ and a C₁₂ to C₁₆ hydrocarbyl group).

Similarly, another representative example follows for the ratio of Mw/Mnof a polypropylene homopolymer consistent with embodiments of thisinvention. By a disclosure that the ratio of Mw/Mn can be in a rangefrom about 2 to about 5, the intent is to recite that the ratio of Mw/Mncan be any ratio in the range and, for example, can be equal to about 2,about 2.5, about 3, about 3.5, about 4, about 4.5, or about 5.Additionally, the ratio of Mw/Mn can be within any range from about 2 toabout 5 (for example, from about 2.2 to about 4.5), and this alsoincludes any combination of ranges between about 2 and about 5 (forexample, the Mw/Mn ratio can be in a range from about 2 to about 3, orfrom about 3.5 to about 5). Likewise, all other ranges disclosed hereinshould be interpreted in a manner similar to these examples.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed generally to metallocene-basedcatalyst systems, methods for preparing the catalyst systems, methodsfor using the catalyst systems to polymerize propylene, the propylenehomopolymer resins produced using such catalyst systems andpolymerization processes, and fabricated articles produced using thesepropylene homopolymer resins.

Polypropylene Homopolymers

Generally, the polymers disclosed herein are polypropylene hompopolymershaving unexpected and beneficial combinations of melt flow rate, peakmelting point, Mw/Mn ratio, and Mz/Mw ratio, and can be produced withoutthe need for vis-breaking processes or the use of peroxide additives(and their detrimental decomposition products). An illustrative andnon-limiting example of a polypropylene homopolymer of the presentinvention can have a melt flow rate in a range from about 200 g/10 minto about 3000 g/10 min, a ratio of Mw/Mn in a range from about 2 toabout 5, and a peak melting point in a range from about 138° C. to about151° C. Another illustrative and non-limiting example of a polypropylenehomopolymer of the present invention can have a melt flow rate in arange from about 200 g/10 min to about 3000 g/10 min, a ratio of Mw/Mnin a range from about 2 to about 5, and a ratio of Mz/Mw in a range fromabout 1.7 to about 3.5. These illustrative and non-limiting examples ofpolypropylene homopolymers consistent with the present invention alsocan have any of the polymer properties listed below and in anycombination.

The peak melting points of polypropylene homopolymers disclosed hereinoften can range from about 138° C. to about 152° C., for example, fromabout 138° C. to about 151° C., or from about 138° C. to about 150° C.In particular embodiments, the peak melting point of the polypropylenehomopolymer can be in a range from about 140° C. to about 152° C., fromabout 140° C. to about 151° C., from about 140° C. to about 150° C.,from about 141° C. to about 151° C., or from about 141° C. to about 149°C.

Consistent with certain embodiments of this invention, polypropylenehomopolymers described herein can have a very high melt flow rate (MFR,230° C.), often in a range from about 200 g/10 min to about 3000 g/10min, from about 300 g/10 min to about 3000 g/10 min, from about 300 g/10min to about 2500 g/10 min, or from about 300 g/10 min to about 2000g/10 min. In further embodiments, polypropylene homopolymers describedherein can have a MFR in a range from about 350 g/10 min to about 2500g/10 min, from about 350 g/10 min to about 2000 g/10 min, from about 500g/10 min to about 2500 g/10 min, or from about 500 g/10 min to about2000 g/10 min.

In an embodiment, propylene homopolymers described herein can have aratio of Mw/Mn, or the polydispersity index, in a range from about 2 toabout 5, from about 2.2 to about 5, from about 2 to about 4.5, or fromabout 2.2 to about 4.5. In another embodiment, propylene homopolymersdescribed herein can have a Mw/Mn in a range from about 2.4 to about 5,from about 2.4 to about 4.5, or from about 2.5 to about 4.5.

In an embodiment, propylene homopolymers described herein can have aratio of Mz/Mw in a range from about 1.7 to about 3.5, from about 1.7 toabout 3, from about 1.8 to about 3.5, or from about 1.8 to about 3. Inanother embodiment, propylene homopolymers described herein can have aMz/Mw in a range from about 1.9 to about 3.3, from about 1.9 to about 3,or from about 1.9 to about 2.8.

In an embodiment, propylene homopolymers described herein can have aweight-average molecular weight (Mw) in a range from about 40,000 g/molto about 110,000 g/mol, from about 40,000 g/mol to about 90,000 g/mol,from about 45,000 g/mol to about 110,000 g/mol, or from about 45,000g/mol to about 85,000 g/mol. Additionally or alternatively, thepropylene homopolymers described herein can have a number-averagemolecular weight (Mn) in a range from about 10,000 g/mol to about 40,000g/mol, from about 10,000 g/mol to about 30,000 g/mol, from about 12,000g/mol to about 35,000 g/mol, or from about 12,000 g/mol to about 28,000g/mol. Additionally or alternatively, the propylene homopolymersdescribed herein can have a z-average molecular weight (Mz) in a rangefrom about 80,000 g/mol to about 230,000 g/mol, from about 90,000 g/molto about 200,000 g/mol, from about 90,000 g/mol to about 180,000 g/mol,or from about 100,000 g/mol to about 170,000 g/mol.

Unexpectedly, the propylene homopolymers of this invention can have arelatively high isotactic content. For instance, the isotacticity [mm]generally can fall within a range from about from about 93% to about99%, from about 93% to about 98%, or from about 93% to about 97%. Insome embodiments, the isotacticity [mm] of the polypropylene homopolymercan range from about from about 94% to about 99%, from about 94% toabout 98%, or from about 96% to about 98%.

Also unexpectedly, the propylene homopolymers of this invention can havea relatively low amount of residual catalyst, e.g., zirconium from themetallocene compound used in the catalyst systems further discussedhereinbelow. This can be due, in part, to the high catalystactivities/productivities of the disclosed catalyst systems, and can bebeneficial for a cleaner homopolymer for thin fiber applications. In oneembodiment, the polypropylene homopolymer can contain from about 10 ppbto about 150 ppb, from about 10 ppb to about 100 ppb, from about 10 ppbto about 80 ppb, or from about 20 ppb to about 150 ppb (parts perbillion by weight) of zirconium, while in another embodiment, thepolypropylene homopolymer can contain from about 20 ppb to about 120ppb, from about 20 ppb to about 80 ppb, from about 30 ppb to about 75ppb, or from about 25 ppb to about 60 ppb (parts per billion by weight)of zirconium.

Moreover, because a vis-breaking step is not necessary to produce thepolypropylene homopolymers disclosed herein, these polypropylenehomopolymer can have substantially no peroxide residue or peroxidedecomposition by-products. In this regard, substantially none means lessthan about 25 ppm (parts per million by weight), and in someembodiments, less than about 10 ppm, less than about 5 ppm, or 0 ppm (nomeasurable amount) of peroxide residue or peroxide decompositionby-products.

Generally, polypropylene homopolymers consistent with certainembodiments of the invention can have a unimodal molecular weightdistribution curve (as determined using gel permeation chromatography(GPC) or other suitable analytical technique). In a unimodal molecularweight distribution curve, there is one identifiable peak in themolecular weight distribution curve. Additionally, the polypropylenehomopolymer described herein can be a reactor product (e.g., a singlereactor product), for example, not a post-reactor blend of two polymers,for instance, having different molecular weight characteristics. As oneof skill in the art would readily recognize, physical blends of twodifferent polymer resins can be made, but this necessitates additionalprocessing and complexity not required for a reactor product.

Articles and Fibers

Articles of manufacture can be formed from, or can comprise, thepolypropylene homopolymers of this invention and, accordingly, areencompassed herein. Articles of manufacture also can be formed from, orcan comprise, the polypropylene homopolymers of this invention and anadditive, non-limiting examples of which can include an antioxidant,acid scavenger, antiblock additive, slip additive, colorant, filler,processing aid, UV inhibitor, and the like, as well as combinationsthereof. Articles which can comprise polypropylene homopolymers of thisinvention can include, but are not limited to, a molded product (e.g.,an injection molded product), a nonwoven article, or a fiber or fabric,and the like. As noted above, these articles also can contain one ormore suitable additives, depending upon the processing techniqueemployed and the end-use application. In some embodiments of thisinvention, an article of manufacture can comprise any of polypropylenehomopolymers described herein, and the article of manufacture can be afiber, or fabric, or nonwoven article.

Also contemplated herein is a method of making a fiber (e.g., ameltblown fiber, a spunbond fiber) comprising any polypropylenehomopolymer disclosed herein. For instance, the method can comprise meltprocessing the polypropylene homopolymer (with or without one or moreadditives) through a fiber die to form the fiber. The melt processingcan involve extruding the polypropylene homopolymer through the fiberdie, but is not limited thereto. Fibers produced in accordance with thismethod also are encompassed herein.

The polypropylene homopolymer fibers can be of any suitable thickness ordiameter, but often can have a fiber thickness or diameter ranging fromabout 0.1 microns to about 20 microns. Other suitable ranges for thefiber thickness or diameter include from about 0.5 microns to about 15microns, from about 1 micron to about 12 microns, or from about 2microns to about 10 microns.

Catalyst Compositions

In accordance with some embodiments of the present invention, thepolypropylene homopolymer can be produced using a metallocene-basedcatalyst system. In further embodiments of the present invention, thepolypropylene homopolymer can be produced using a singlemetallocene-based catalyst system. In these embodiments, the singlemetallocene compound can be a bridged metallocene compound, forinstance, a racemic ansa-bis(indenyl)zirconocene compound. Generally,the racemic ansa-bis(indenyl)zirconocene compound can contain a silicon,carbon, or germanium bridging atom as part of the bridging group.Additionally or alternatively, the indenyl groups of the metallocenecompound can be substituted indenyl groups, for instance, substitutedwith any suitable substituent, any suitable number of substituents, andat any suitable position(s) that conform(s) to the rules of chemicalvalence. Additionally or alternatively, the indenyl groups of themetallocene compound can have a phenyl or substituted phenylsubstituent. Additionally or alternatively, the bridged metallocenecompound can contain an alkenyl substituent, and the alkenyl substituentcan be on the indenyl groups, the alkenyl substituent can be part of thebridging group (e.g., a substituent off of the bridging atom), or analkenyl substituent can be on the indenyl groups and the same or adifferent alkenyl substituent can be part of the bridging group.

The racemic ansa-bis(indenyl)zirconocene compound can comprise, inparticular embodiments of this invention, a bridged metallocene compoundhaving formula (A):

rac-E(InR_(n))₂ZrX₂  (A).

Within formula (A), E, In, each R, n, and each X are independentelements of the bridged metallocene compound. Accordingly, the bridgedmetallocene compound having formula (A) can be described using anycombination of E, In, R, n, and X disclosed herein.

Each X in formula (A) independently can be a monoanionic ligand. In someembodiments, suitable monoanionic ligands can include, but are notlimited to, H (hydride), BH₄, a halide, a C₁ to C₃₆ hydrocarbyl group, aC₁ to C₃₆ hydrocarboxy group, a C₁ to C₃₆ hydrocarbylaminyl group, a C₁to C₃₆ hydrocarbylsilyl group, a C₁ to C₃₆ hydrocarbylaminylsilyl group,—OBR^(Z) ₂, or —OSO₂R^(Z), wherein R^(Z) is a C₁ to C₃₆ hydrocarbylgroup. It is contemplated that each X can be either the same or adifferent monoanionic ligand.

In one embodiment, each X independently can be H, BH₄, a halide (e.g.,F, Cl, and Br), a C₁ to C₁₈ hydrocarbyl group, a C₁ to C₁₈ hydrocarboxygroup, a C₁ to C₁₈ hydrocarbylaminyl group, a C₁ to C₁₈ hydrocarbylsilylgroup, or a C₁ to C₁₈ hydrocarbylaminylsilyl group. Alternatively, eachX independently can be H, BH₄, a halide, OBR^(Z) ₂, or OSO₂R^(Z),wherein R^(Z) is a C₁ to C₁₈ hydrocarbyl group. In another embodiment,each X independently can be H, BH₄, a halide, a C₁ to C₁₂ hydrocarbylgroup, a C₁ to C₁₂ hydrocarboxy group, a C₁ to C₁₂ hydrocarbylaminylgroup, a C₁ to C₁₂ hydrocarbylsilyl group, a C₁ to C₁₂hydrocarbylaminylsilyl group, OBR^(Z) ₂, or OSO₂R^(Z), wherein R^(Z) isa C₁ to C₁₂ hydrocarbyl group. In another embodiment, each Xindependently can be H, BH₄, a halide, a C₁ to C₁₀ hydrocarbyl group, aC₁ to C₁₀ hydrocarboxy group, a C₁ to C₁₀ hydrocarbylaminyl group, a C₁to C₁₀ hydrocarbylsilyl group, a C₁ to C₁₀ hydrocarbylaminylsilyl group,OBR^(Z) ₂, or OSO₂R^(Z), wherein R^(Z) is a C₁ to C₁₀ hydrocarbyl group.In yet another embodiment, each X independently can be H, BH₄, a halide,a C₁ to C₈ hydrocarbyl group, a C₁ to C₈ hydrocarboxy group, a C₁ to C₈hydrocarbylaminyl group, a C₁ to C₈ hydrocarbylsilyl group, a C₁ to C₈hydrocarbylaminylsilyl group, OBR^(Z) ₂, or OSO₂R^(Z), wherein R^(Z) isa C₁ to C₈ hydrocarbyl group. In still another embodiment, each Xindependently can be a halide or a C₁ to C₁₈ hydrocarbyl group. Forexample, each X can be Cl.

The hydrocarbyl group which can be an X (one or both) in formula (A) canbe a C₁ to C₃₆ hydrocarbyl group, including, but not limited to, a C₁ toC₃₆ alkyl group, a C₂ to C₃₆ alkenyl group, a C₄ to C₃₆ cycloalkylgroup, a C₆ to C₃₆ aryl group, or a C₇ to C₃₆ aralkyl group. Forinstance, each X independently can be a C₁ to C₁₈ alkyl group, a C₂ toC₁₈ alkenyl group, a C₄ to C₁₈ cycloalkyl group, a C₆ to C₁₈ aryl group,or a C₇ to C₁₈ aralkyl group; alternatively, each X independently can bea C₁ to C₁₂ alkyl group, a C₂ to C₁₂ alkenyl group, a C₄ to C₁₂cycloalkyl group, a C₆ to C₁₂ aryl group, or a C₇ to C₁₂ aralkyl group;alternatively, each X independently can be a C₁ to C₁₀ alkyl group, a C₂to C₁₀ alkenyl group, a C₄ to C₁₀ cycloalkyl group, a C₆ to C₁₀ arylgroup, or a C₇ to C₁₀ aralkyl group; or alternatively, each Xindependently can be a C₁ to C₅ alkyl group, a C₂ to C₅ alkenyl group, aC₅ to C₈ cycloalkyl group, a C₆ to C₈ aryl group, or a C₇ to C₈ aralkylgroup.

Accordingly, in some embodiments, the alkyl group which can be an X informula (A) can be a methyl group, an ethyl group, a propyl group, abutyl group, a pentyl group, a hexyl group, a heptyl group, an octylgroup, a nonyl group, a decyl group, a undecyl group, a dodecyl group, atridecyl group, a tetradecyl group, a pentadecyl group, a hexadecylgroup, a heptadecyl group, or an octadecyl group; or alternatively, amethyl group, an ethyl group, a propyl group, a butyl group, a pentylgroup, a hexyl group, a heptyl group, an octyl group, a nonyl group, ora decyl group. In some embodiments, the alkyl group which can be an X informula (A) can be a methyl group, an ethyl group, a n-propyl group, aniso-propyl group, a n-butyl group, an iso-butyl group, a sec-butylgroup, a tert-butyl group, a n-pentyl group, an iso-pentyl group, asec-pentyl group, or a neopentyl group; alternatively, a methyl group,an ethyl group, an iso-propyl group, a tert-butyl group, or a neopentylgroup; alternatively, a methyl group; alternatively, an ethyl group;alternatively, a n-propyl group; alternatively, an iso-propyl group;alternatively, a tert-butyl group; or alternatively, a neopentyl group.

Suitable alkenyl groups which can be an X in formula (A) can include,but are not limited to, an ethenyl group, a propenyl group, a butenylgroup, a pentenyl group, a hexenyl group, a heptenyl group, an octenylgroup, a nonenyl group, a decenyl group, a undecenyl group, a dodecenylgroup, a tridecenyl group, a tetradecenyl group, a pentadecenyl group, ahexadecenyl group, a heptadecenyl group, or an octadecenyl group. Suchalkenyl groups can be linear or branched, and the double bond can belocated anywhere in the chain. In one embodiment, each X in formula (A)independently can be an ethenyl group, a propenyl group, a butenylgroup, a pentenyl group, a hexenyl group, a heptenyl group, an octenylgroup, a nonenyl group, or a decenyl group, while in another embodiment,each X in formula (A) independently can be an ethenyl group, a propenylgroup, a butenyl group, a pentenyl group, or a hexenyl group. Forexample, an X can be an ethenyl group; alternatively, a propenyl group;alternatively, a butenyl group; alternatively, a pentenyl group; oralternatively, a hexenyl group. In yet another embodiment, an X can be aterminal alkenyl group, such as a C₃ to C₁₈ terminal alkenyl group, a C₃to C₁₂ terminal alkenyl group, or a C₃ to C₈ terminal alkenyl group.Illustrative terminal alkenyl groups can include, but are not limitedto, a prop-2-en-1-yl group, a bute-3-en-1-yl group, a pent-4-en-1-ylgroup, a hex-5-en-1-yl group, a hept-6-en-1-yl group, an octe-7-en-1-ylgroup, a non-8-en-1-yl group, a dece-9-en-1-yl group, and so forth.

Each X in formula (A) independently can be a cycloalkyl group,including, but not limited to, a cyclobutyl group, a substitutedcyclobutyl group, a cyclopentyl group, a substituted cyclopentyl group,a cyclohexyl group, a substituted cyclohexyl group, a cycloheptyl group,a substituted cycloheptyl group, a cyclooctyl group, or a substitutedcyclooctyl group. For example, an X in formula (A) can be a cyclopentylgroup, a substituted cyclopentyl group, a cyclohexyl group, or asubstituted cyclohexyl group. Moreover, each X in formula (A)independently can be a cyclobutyl group or a substituted cyclobutylgroup; alternatively, a cyclopentyl group or a substituted cyclopentylgroup; alternatively, a cyclohexyl group or a substituted cyclohexylgroup; alternatively, a cycloheptyl group or a substituted cycloheptylgroup; alternatively, a cyclooctyl group or a substituted cyclooctylgroup; alternatively, a cyclopentyl group; alternatively, a substitutedcyclopentyl group; alternatively, a cyclohexyl group; or alternatively,a substituted cyclohexyl group. Substituents which can be utilized forthe substituted cycloalkyl group are independently disclosed herein andcan be utilized without limitation to further describe the substitutedcycloalkyl group which can be an X in formula (A).

In some embodiments, the aryl group which can be an X in formula (A) canbe a phenyl group, a substituted phenyl group, a naphthyl group, or asubstituted naphthyl group. In an embodiment, the aryl group can be aphenyl group or a substituted phenyl group; alternatively, a naphthylgroup or a substituted naphthyl group; alternatively, a phenyl group ora naphthyl group; alternatively, a substituted phenyl group or asubstituted naphthyl group; alternatively, a phenyl group; oralternatively, a naphthyl group. Substituents which can be utilized forthe substituted phenyl groups or substituted naphthyl groups areindependently disclosed herein and can be utilized without limitation tofurther describe the substituted phenyl groups or substituted naphthylgroups which can be an X in formula (A).

In an embodiment, the substituted phenyl group which can be an X informula (A) can be a 2-substituted phenyl group, a 3-substituted phenylgroup, a 4-substituted phenyl group, a 2,4-disubstituted phenyl group, a2,6-disubstituted phenyl group, a 3,5-disubstituted phenyl group, or a2,4,6-trisubstituted phenyl group. In other embodiments, the substitutedphenyl group can be a 2-substituted phenyl group, a 4-substituted phenylgroup, a 2,4-disubstituted phenyl group, or a 2,6-disubstituted phenylgroup; alternatively, a 3-substituted phenyl group or a3,5-disubstituted phenyl group; alternatively, a 2-substituted phenylgroup or a 4-substituted phenyl group; alternatively, a2,4-disubstituted phenyl group or a 2,6-disubstituted phenyl group;alternatively, a 2-substituted phenyl group; alternatively, a3-substituted phenyl group; alternatively, a 4-substituted phenyl group;alternatively, a 2,4-disubstituted phenyl group; alternatively, a2,6-disubstituted phenyl group; alternatively, a 3,5-disubstitutedphenyl group; or alternatively, a 2,4,6-trisubstituted phenyl group.Substituents which can be utilized for these specific substituted phenylgroups are independently disclosed herein and can be utilized withoutlimitation to further describe these substituted phenyl groups which canbe an X in formula (A).

In some embodiments, the aralkyl group which can be an X in formula (A)can be a benzyl group or a substituted benzyl group. In an embodiment,the aralkyl group can be a benzyl group or, alternatively, a substitutedbenzyl group. Substituents which can be utilized for the substitutedaralkyl group are independently disclosed herein and can be utilizedwithout limitation to further describe the substituted aralkyl groupwhich can be an X in formula (A).

In an embodiment, each non-hydrogen substituent(s) for the substitutedcycloalkyl group, substituted aryl group, or substituted aralkyl groupwhich can be an X in formula (A) independently can be a C₁ to C₁₈hydrocarbyl group; alternatively, a C₁ to C₈ hydrocarbyl group; oralternatively, a C₁ to C₅ hydrocarbyl group. Specific hydrocarbyl groupsare independently disclosed herein and can be utilized withoutlimitation to further describe the substituents of the substitutedcycloalkyl groups, substituted aryl groups, or substituted aralkylgroups which can be an X in formula (A). For instance, the hydrocarbylsubstituent can be an alkyl group, such as a methyl group, an ethylgroup, a n-propyl group, an isopropyl group, a n-butyl group, asec-butyl group, an isobutyl group, a tert-butyl group, a n-pentylgroup, a 2-pentyl group, a 3-pentyl group, a 2-methyl-1-butyl group, atert-pentyl group, a 3-methyl-1-butyl group, a 3-methyl-2-butyl group,or a neo-pentyl group, and the like. Furthermore, the hydrocarbylsubstituent can be a benzyl group, a phenyl group, a tolyl group, or axylyl group, and the like.

A hydrocarboxy group is used generically herein to include, forinstance, alkoxy, aryloxy, aralkoxy, -(alkyl, aryl, oraralkyl)-O-(alkyl, aryl, or aralkyl) groups, and —O(CO)-(hydrogen orhydrocarbyl) groups, and these groups can comprise up to about 36 carbonatoms (e.g., C₁ to C₃₆, C₁ to C₁₈, C₁ to C₁₀, or C₁ to C₈ hydrocarboxygroups). Illustrative and non-limiting examples of hydrocarboxy groupswhich can be an X in formula (A) can include, but are not limited to, amethoxy group, an ethoxy group, an n-propoxy group, an isopropoxy group,an n-butoxy group, a sec-butoxy group, an isobutoxy group, a tert-butoxygroup, an n-pentoxy group, a 2-pentoxy group, a 3-pentoxy group, a2-methyl-1-butoxy group, a tert-pentoxy group, a 3-methyl-1-butoxygroup, a 3-methyl-2-butoxy group, a neo-pentoxy group, a phenoxy group,a toloxy group, a xyloxy group, a 2,4,6-trimethylphenoxy group, abenzoxy group, an acetylacetonate group (acac), a formate group, anacetate group, a stearate group, an oleate group, a benzoate group, andthe like. In an embodiment, the hydrocarboxy group which can be an X informula (A) can be a methoxy group; alternatively, an ethoxy group;alternatively, an n-propoxy group; alternatively, an isopropoxy group;alternatively, an n-butoxy group; alternatively, a sec-butoxy group;alternatively, an isobutoxy group; alternatively, a tert-butoxy group;alternatively, an n-pentoxy group; alternatively, a 2-pentoxy group;alternatively, a 3-pentoxy group; alternatively, a 2-methyl-1-butoxygroup; alternatively, a tert-pentoxy group; alternatively, a3-methyl-1-butoxy group, alternatively, a 3-methyl-2-butoxy group;alternatively, a neo-pentoxy group; alternatively, a phenoxy group;alternatively, a toloxy group; alternatively, a xyloxy group;alternatively, a 2,4,6-trimethylphenoxy group; alternatively, a benzoxygroup; alternatively, an acetylacetonate group; alternatively, a formategroup; alternatively, an acetate group; alternatively, a stearate group;alternatively, an oleate group; or alternatively, a benzoate group.

The term hydrocarbylaminyl group is used generically herein to refercollectively to, for instance, alkylaminyl, arylaminyl, aralkylaminyl,dialkylaminyl, diarylaminyl, diaralkylaminyl, and -(alkyl, aryl, oraralkyl)-N-(alkyl, aryl, or aralkyl) groups, and unless otherwisespecified, the hydrocarbylaminyl groups which can be an X in formula (A)can comprise up to about 36 carbon atoms (e.g., C₁ to C₃₆, C₁ to C₁₈, C₁to C₁₀, or C₁ to C₈ hydrocarbylaminyl groups). Accordingly,hydrocarbylaminyl is intended to cover both (mono)hydrocarbylaminyl anddihydrocarbylaminyl groups. In some embodiments, the hydrocarbylaminylgroup which can be an X in formula (A) can be, for instance, amethylaminyl group (—NHCH₃), an ethylaminyl group (—NHCH₂CH₃), ann-propylaminyl group (—NHCH₂CH₂CH₃), an iso-propylaminyl group(—NHCH(CH₃)₂), an n-butylaminyl group (—NHCH₂CH₂CH₂CH₃), a t-butylaminylgroup (—NHC(CH₃)₃), an n-pentylaminyl group (—NHCH₂CH₂CH₂CH₂CH₃), aneo-pentylaminyl group (—NHCH₂C(CH₃)₃), a phenylaminyl group (—NHC₆H₅),a tolylaminyl group (—NHC₆H₄CH₃), or a xylylaminyl group(—NHC₆H₃(CH₃)₂); alternatively, a methylaminyl group; alternatively, anethylaminyl group; alternatively, a propylaminyl group; oralternatively, a phenylaminyl group. In other embodiments, thehydrocarbylaminyl group which can be an X in formula (A) can be, forinstance, a dimethylaminyl group (—N(CH₃)₂), a diethylaminyl group(—N(CH₂CH₃)₂), a di-n-propylaminyl group (—N(CH₂CH₂CH₃)₂), adi-iso-propylaminyl group (—N(CH(CH₃)₂)₂), a di-n-butylaminyl group(—N(CH₂CH₂CH₂CH₃)₂), a di-t-butylaminyl group (—N(C(CH₃)₃)₂), adi-n-pentylaminyl group (—N(CH₂CH₂CH₂CH₂CH₃)₂), a di-neo-pentylaminylgroup (—N(CH₂C(CH₃)₃)₂), a di-phenylaminyl group (—N(C₆H₅)₂), adi-tolylaminyl group (—N(C₆H₄CH₃)₂), or a di-xylylaminyl group(—N(C₆H₃(CH₃)₂)₂); alternatively, a dimethylaminyl group; alternatively,a di-ethylaminyl group; alternatively, a di-n-propylaminyl group; oralternatively, a di-phenylaminyl group.

In accordance with some embodiments disclosed herein, each Xindependently can be a C₁ to C₃₆ hydrocarbylsilyl group; alternatively,a C₁ to C₂₄ hydrocarbylsilyl group; alternatively, a C₁ to C₁₈hydrocarbylsilyl group; or alternatively, a C₁ to C₈ hydrocarbylsilylgroup. In an embodiment, each hydrocarbyl (one or more) of thehydrocarbylsilyl group can be any hydrocarbyl group disclosed herein(e.g., a C₁ to C₅ alkyl group, a C₂ to C₅ alkenyl group, a C₅ to C₈cycloalkyl group, a C₆ to C₈ aryl group, or a C₇ to C₈ aralkyl group).As used herein, hydrocarbylsilyl is intended to cover(mono)hydrocarbylsilyl (—SiH₂R), dihydrocarbylsilyl (—SiHR₂), andtrihydrocarbylsilyl (—SiR₃) groups, with R being a hydrocarbyl group. Inone embodiment, the hydrocarbylsilyl group can be a C₃ to C₃₆ or a C₃ toC₁₈ trihydrocarbylsilyl group, such as, for example, a trialkylsilylgroup or a triphenylsilyl group. Illustrative and non-limiting examplesof hydrocarbylsilyl groups which can be an X in formula (A) can include,but are not limited to, trimethylsilyl, triethylsilyl, tripropylsilyl(e.g., triisopropylsilyl), tributylsilyl, tripentylsilyl,triphenylsilyl, allyldimethylsilyl, and the like.

A hydrocarbylaminylsilyl group is used herein to refer to groupscontaining at least one hydrocarbon moiety, at least one N atom, and atleast one Si atom. Illustrative and non-limiting examples ofhydrocarbylaminylsilyl groups which can be an X include, but are notlimited to, —N(SiMe₃)₂, —N(SiEt₃)₂, and the like. Unless otherwisespecified, the hydrocarbylaminylsilyl groups which can be an X cancomprise up to about 36 carbon atoms (e.g., C₁ to C₃₆, C₁ to C₁₈, C₁ toC₁₂, or C₁ to C₈ hydrocarbylaminylsilyl groups). In an embodiment, eachhydrocarbyl (one or more) of the hydrocarbylaminylsilyl group can be anyhydrocarbyl group disclosed herein (e.g., a C₁ to C₅ alkyl group, a C₂to C₅ alkenyl group, a C₅ to C₈ cycloalkyl group, a C₆ to C₈ aryl group,or a C₇ to C₈ aralkyl group). Moreover, hydrocarbylaminylsilyl isintended to cover —NH(SiH₂R), —NH(SiHR₂), —NH(SiR₃), —N(SiH₂R)₂,—N(SiHR₂)₂, and —N(SiR₃)₂ groups, among others, with R being ahydrocarbyl group.

In an embodiment, each X independently can be —OBR^(Z) ₂ or —OSO₂R^(Z),wherein R^(Z) is a C₁ to C₃₆ hydrocarbyl group, or alternatively, a C₁to C₁₈ hydrocarbyl group. The hydrocarbyl group in OBR^(Z) ₂ andOSO₂R^(Z) independently can be any hydrocarbyl group disclosed herein,such as, for instance, a C₁ to C₁₈ alkyl group, a C₂ to C₁₈ alkenylgroup, a C₄ to C₁₈ cycloalkyl group, a C₆ to C₁₈ aryl group, or a C₇ toC₁₈ aralkyl group; alternatively, a C₁ to C₁₂ alkyl group, a C₂ to C₁₂alkenyl group, a C₄ to C₁₂ cycloalkyl group, a C₆ to C₁₂ aryl group, ora C₇ to C₁₂ aralkyl group; or alternatively, a C₁ to C₈ alkyl group, aC₂ to C₈ alkenyl group, a C₅ to C₈ cycloalkyl group, a C₆ to C₈ arylgroup, or a C₇ to C₈ aralkyl group.

In one embodiment, each X independently can be H, BH₄, a halide, or a C₁to C₃₆ hydrocarbyl group, hydrocarboxy group, hydrocarbylaminyl group,hydrocarbylsilyl group, or hydrocarbylaminylsilyl group, while inanother embodiment, each X independently can be H, BH₄, or a C₁ to C₁₈hydrocarboxy group, hydrocarbylaminyl group, hydrocarbylsilyl group, orhydrocarbylaminylsilyl group. In yet another embodiment, each Xindependently can be a halide; alternatively, a C₁ to C₁₈ hydrocarbylgroup; alternatively, a C₁ to C₁₈ hydrocarboxy group; alternatively, aC₁ to C₁₈ hydrocarbylaminyl group; alternatively, a C₁ to C₁₈hydrocarbylsilyl group; or alternatively, a C₁ to C₁₈hydrocarbylaminylsilyl group. In still another embodiment, both X's canbe H; alternatively, F; alternatively, Cl; alternatively, Br;alternatively, I; alternatively, BH₄; alternatively, a C₁ to C₁₈hydrocarbyl group; alternatively, a C₁ to C₁₈ hydrocarboxy group;alternatively, a C₁ to C₁₈ hydrocarbylaminyl group; alternatively, a C₁to C₁₈ hydrocarbylsilyl group; or alternatively, a C₁ to C₁₈hydrocarbylaminylsilyl group.

Each X independently can be, in some embodiments, H, a halide, methyl,phenyl, benzyl, an alkoxy, an aryloxy, acetylacetonate, formate,acetate, stearate, oleate, benzoate, an alkylaminyl, a dialkylaminyl, atrihydrocarbylsilyl, or a hydrocarbylaminylsilyl; alternatively, H, ahalide, methyl, phenyl, or benzyl; alternatively, an alkoxy, an aryloxy,or acetylacetonate; alternatively, an alkylaminyl or a dialkylaminyl;alternatively, a trihydrocarbylsilyl or hydrocarbylaminylsilyl;alternatively, H or a halide; alternatively, methyl, phenyl, benzyl, analkoxy, an aryloxy, acetylacetonate, an alkylaminyl, or a dialkylaminyl;alternatively, H; alternatively, a halide; alternatively, methyl;alternatively, phenyl; alternatively, benzyl; alternatively, an alkoxy;alternatively, an aryloxy; alternatively, acetylacetonate;alternatively, an alkylaminyl; alternatively, a dialkylaminyl;alternatively, a trihydrocarbylsilyl; or alternatively, ahydrocarbylaminylsilyl. In these and other embodiments, the alkoxy,aryloxy, alkylaminyl, dialkylaminyl, trihydrocarbylsilyl, andhydrocarbylaminylsilyl can be a C₁ to C₃₆, a C₁ to C₁₈, a C₁ to C₁₂, ora C₁ to C₈ alkoxy, aryloxy, alkylaminyl, dialkylaminyl,trihydrocarbylsilyl, and hydrocarbylaminylsilyl.

Moreover, each X independently can be, in certain embodiments, a halideor a C₁ to C₁₈ hydrocarbyl group; alternatively, a halide or a C₁ to C₈hydrocarbyl group; alternatively, F, Cl, Br, I, methyl, benzyl, orphenyl; alternatively, Cl, methyl, benzyl, or phenyl; alternatively, aC₁ to C₁₈ alkoxy, aryloxy, alkylaminyl, dialkylaminyl,trihydrocarbylsilyl, or hydrocarbylaminylsilyl group; alternatively, aC₁ to C₈ alkoxy, aryloxy, alkylaminyl, dialkylaminyl, trihydrocarbylsilyl, or hydrocarbylaminyl silyl group; or alternatively, methyl,ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl,ethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl,nonenyl, decenyl, phenyl, tolyl, benzyl, naphthyl, trimethylsilyl,triisopropylsilyl, triphenylsilyl, or allyldimethylsilyl.

In formula (A), In is an indenyl group, either substituted orunsubstituted, and the integer n can be any integer from 0 to 6(inclusive). In one embodiment, therefore, n can be equal to 0, and Incan be an unsubstituted indenyl group. Alternatively, In can be asubstituted indenyl group, having from 1 up to 6 substituents. Inanother embodiment, n can be from 1 to 5, from 1 to 4, from 1 to 3, from2 to 4, equal to 1, or equal to 2.

If present, each substituent R on In independently can be H, a halide, aC₁ to C₃₆ hydrocarbyl group, a C₁ to C₃₆ halogenated hydrocarbyl group,a C₁ to C₃₆ hydrocarboxy group, or a C₁ to C₃₆ hydrocarbylsilyl group.Each substituent on In can be either the same or a different substituentgroup. Moreover, each substituent can be at any position on the indenylring structure that conforms with the rules of chemical valence. In anembodiment, two or more substituents on In can be different, oralternatively, each substituent on In can be the same. As noted above,if substituted, the indenyl group In can have one substituent (n isequal to 1), two substituents (n is equal to 2), three substituents (nis equal to 3), and so forth.

In formula (A), each substituent R on the indenyl group In independentlycan be H, a halide, a C₁ to C₃₆ hydrocarbyl group, a C₁ to C₃₆halogenated hydrocarbyl group, a C₁ to C₃₆ hydrocarboxy group, or a C₁to C₃₆ hydrocarbylsilyl group. In some embodiments, each substituentindependently can be H; alternatively, a halide; alternatively, a C₁ toC₁₈ hydrocarbyl group; alternatively, a C₁ to C₁₈ halogenatedhydrocarbyl group; alternatively, a C₁ to C₁₈ hydrocarboxy group;alternatively, a C₁ to C₁₈ hydrocarbylsilyl group; alternatively, a C₁to C₁₂ hydrocarbyl group or a C₁ to C₁₂ hydrocarbylsilyl group; oralternatively, a C₁ to C₈ alkyl group or a C₃ to C₈ alkenyl group. Thehalide, C₁ to C₃₆ hydrocarbyl group, C₁ to C₃₆ hydrocarboxy group, andC₁ to C₃₆ hydrocarbylsilyl group which can be R in formula (A) can beany halide, C₁ to C₃₆ hydrocarbyl group, C₁ to C₃₆ hydrocarboxy group,and C₁ to C₃₆ hydrocarbylsilyl group described herein (e.g., aspertaining to X in formula (A)). A substituent R on In in formula (A)can be, in certain embodiments, a C₁ to C₃₆ halogenated hydrocarbylgroup, where the halogenated hydrocarbyl group indicates the presence ofone or more halogen atoms replacing an equivalent number of hydrogenatoms in the hydrocarbyl group. The halogenated hydrocarbyl group oftencan be a halogenated alkyl group, a halogenated alkenyl group, ahalogenated cycloalkyl group, a halogenated aryl group, or a halogenatedaralkyl group. Representative and non-limiting halogenated hydrocarbylgroups include pentafluorophenyl, trifluoromethyl (CF₃), and the like.

As a non-limiting example, each R independently can be H, Cl, CF₃, amethyl group, an ethyl group, a propyl group, a butyl group (e.g.,t-Bu), a pentyl group, a hexyl group, a heptyl group, an octyl group, anonyl group, a decyl group, an ethenyl group, a propenyl group, abutenyl group, a pentenyl group, a hexenyl group, a heptenyl group, anoctenyl group, a nonenyl group, a decenyl group, a phenyl group, analkyl-substituted phenyl group (e.g., a t-Bu-phenyl group), a benzylgroup, a naphthyl group, a carbazolyl group, a trimethylsilyl group, atriisopropylsilyl group, a triphenylsilyl group, or anallyldimethylsilyl group; alternatively, H; alternatively, Cl;alternatively, CF₃; alternatively, a methyl group; alternatively, anethyl group; alternatively, a propyl group; alternatively, a butylgroup; alternatively, a pentyl group; alternatively, a hexyl group;alternatively, a heptyl group; alternatively, an octyl group, a nonylgroup; alternatively, a decyl group; alternatively, an ethenyl group;alternatively, a propenyl group; alternatively, a butenyl group;alternatively, a pentenyl group; alternatively, a hexenyl group;alternatively, a heptenyl group; alternatively, an octenyl group;alternatively, a nonenyl group; alternatively, a decenyl group;alternatively, a phenyl group (or alkyl-substituted phenyl group);alternatively, a tolyl group; alternatively, a benzyl group;alternatively, a naphthyl group; alternatively, a trimethylsilyl group;alternatively, a triisopropylsilyl group; alternatively, atriphenylsilyl group; or alternatively, an allyldimethylsilyl group.

In one embodiment, each R independently can be a C₁ to C₁₈ hydrocarbylgroup. In another embodiment, at least one R can be a C₁ to C₁₂hydrocarbyl group; alternatively, a C₁ to C₈ alkyl or alkenyl group; oralternatively, a C₁ to C₆ alkyl group. In yet another embodiment, atleast one R can be a C₁ to C₈ alkyl group, a C₃ to C₈ terminal alkenylgroup, a phenyl group, or a C₇ to C₁₈ (or C₇ to C₁₂) alkyl-substitutedphenyl group. In still another embodiment, n can be equal to 2, and oneR can be an alkyl or alkenyl group (e.g., having up to 18 carbon atoms,up to 12 carbon atoms, or up to 6 carbon atoms), and the other R can bea phenyl or alkyl-substituted phenyl group (having up to 18 carbonatoms, up to 12 carbon atoms, or up to 10 carbon atoms).

Bridging group E in formula (A) can be a bridging group having theformula >E^(A)R¹R², wherein E^(A) can be a carbon, silicon, or germaniumbridging atom, and R¹ and R² independently can be any substituentdisclosed herein. The “>” in this formula is meant to indicate thatbridging atom E^(A) is a bridge between the two indenyl groups.

In one embodiment of this invention, E^(A) can be a carbon atom, whilein another embodiment, E^(A) can be a silicon atom. In these and otherembodiments, R¹ and R² independently can be H, a halide, a C₁ to C₃₆hydrocarbyl group, a C₁ to C₃₆ halogenated hydrocarbyl group, a C₁ toC₃₆ hydrocarboxy group, or a C₁ to C₃₆ hydrocarbylsilyl group;alternatively, H or a C₁ to C₁₈ hydrocarbyl group; alternatively, H or aC₁ to C₁₂ hydrocarbyl group; alternatively, a C₁ to C₈ hydrocarbylgroup; alternatively, a phenyl group, a C₁ to C₈ alkyl group, or a C₃ toC₈ terminal alkenyl group; or alternatively, a methyl group, an ethylgroup, a propyl group, a butyl group, a pentyl group, a hexyl group, aheptyl group, an octyl group, a nonyl group, a decyl group, an ethenylgroup, a propenyl group, a butenyl group, a pentenyl group, a hexenylgroup, a heptenyl group, an octenyl group, a nonenyl group, a decenylgroup, a phenyl group, a cyclohexylphenyl group, a naphthyl group, atolyl group, or a benzyl group. For instance, at least one of R¹ and R²can be a phenyl group, at least one of R¹ and R² can be an alkyl group(e.g., a C₁ to C₈ alkyl group), or at least one of R¹ and R² can be analkenyl group (e.g., a C₃ to C₈ terminal alkenyl group). As an example,R¹ and R² can be phenyl groups, or R¹ can be a C₁ to C₈ alkyl group andR² can be a C₃ to C₈ terminal alkenyl group, or R¹ can be a phenyl groupand R² can be a C₃ to C₈ terminal alkenyl group, and so forth.

Illustrative and non-limiting examples of racemicansa-bis(indenyl)zirconocene compounds having formula (A) and suitablefor use as a metallocene compound in catalyst compositions of thisinvention can include the following compounds (Me=methyl):

and the like, as well as combinations thereof.

Typically, the catalyst compositions of this invention comprise aracemic ansa-bis(indenyl)zirconocene compound, an activator-support, andan optional co-catalyst. The activator-support can comprise any suitablesolid oxide treated with any suitable electron-withdrawing anion.Examples of such materials are disclosed in, for instance, U.S. Pat.Nos. 7,294,599, 7,601,665, 7,884,163, 8,309,485, 8,623,973, and9,023,959, which are incorporated herein by reference in their entirety.For instance, the activator-support can comprise fluorided alumina,chlorided alumina, bromided alumina, sulfated alumina, fluoridedsilica-alumina, chlorided silica-alumina, bromided silica-alumina,sulfated silica-alumina, fluorided silica-zirconia, chloridedsilica-zirconia, bromided silica-zirconia, sulfated silica-zirconia,fluorided silica-titania, fluorided-chlorided silica-coated alumina,fluorided silica-coated alumina, sulfated silica-coated alumina, orphosphated silica-coated alumina, and the like, as well as anycombination thereof. In another embodiment, the activator-support cancomprise a fluorided solid oxide, a sulfated solid oxide, or acombination thereof. In this embodiment, the activator-support cancomprise fluorided alumina, sulfated alumina, fluorided silica-alumina,sulfated silica-alumina, fluorided silica-coated alumina,fluorided-chlorided silica-coated alumina, sulfated silica-coatedalumina, and the like, as well as any combination thereof.

Various processes can be used to form activator-supports useful in thepresent invention. Methods of contacting the solid oxide with theelectron-withdrawing component, suitable electron withdrawing componentsand addition amounts, impregnation with metals or metal ions (e.g.,zinc, nickel, vanadium, titanium, silver, copper, gallium, tin,tungsten, molybdenum, zirconium, and the like, or combinations thereof),and various calcining procedures and conditions are disclosed in, forexample, U.S. Pat. Nos. 6,107,230, 6,165,929, 6,294,494, 6,300,271,6,316,553, 6,355,594, 6,376,415, 6,388,017, 6,391,816, 6,395,666,6,524,987, 6,548,441, 6,548,442, 6,576,583, 6,613,712, 6,632,894,6,667,274, 6,750,302, 7,294,599, 7,601,665, 7,884,163, and 8,309,485,which are incorporated herein by reference in their entirety. Othersuitable processes and procedures for preparing activator-supports(e.g., fluorided solid oxides or sulfated solid oxides) are well knownto those of skill in the art.

The present invention can employ catalyst compositions containing aracemic ansa-bis(indenyl)zirconocene compound (one or more than one), anactivator-support (one or more than one), and optionally, a co-catalyst.When present, the co-catalyst can include, but is not limited to, metalalkyl, or organometal, co-catalysts, with the metal encompassing boron,aluminum, and the like. Optionally, the catalyst systems provided hereincan comprise a co-catalyst, or a combination of co-catalysts. Forinstance, alkyl borons, alkyl aluminums, or combinations thereof, oftencan be used as co-catalysts in such catalyst systems. Representativeboron compounds can include, but are not limited to, tri-n-butyl borane,tripropylborane, triethylborane, and the like, and this includecombinations of two or more of these materials. While not being limitedthereto, representative aluminum compounds (e.g., organoaluminumcompounds) can include, trimethylaluminum, triethylaluminum,tri-n-propylaluminum, tri-n-butylaluminum, triisobutylaluminum,tri-n-hexylaluminum, tri-n-octylaluminum, diisobutylaluminum hydride,diethylaluminum ethoxide, diethylaluminum chloride, and the like, aswell as any combination thereof.

Co-catalysts that can be used in the catalyst compositions of thisinvention are not limited to the co-catalysts described above. Othersuitable co-catalysts are well known to those of skill in the artincluding, for example, those disclosed in U.S. Pat. Nos. 3,242,099,4,794,096, 4,808,561, 5,576,259, 5,807,938, 5,919,983, 7,294,5997,601,665, 7,884,163, 8,114,946, and 8,309,485, which are incorporatedherein by reference in their entirety.

In another embodiment of the present invention, a catalyst compositionis provided which comprises a racemic ansa-bis(indenyl)zirconocenecompound, an activator-support, and an organoaluminum compound, whereinthis catalyst composition is substantially free of aluminoxanes,organoboron or organoborate compounds, ionizing ionic compounds, andother similar materials; alternatively, substantially free ofaluminoxanes; alternatively, substantially free or organoboron ororganoborate compounds; or alternatively, substantially free of ionizingionic compounds. In these embodiments, the catalyst composition hascatalyst activity, discussed below, in the absence of these additionalmaterials. For example, a catalyst composition of the present inventioncan consist essentially of a racemic ansa-bis(indenyl)zirconocenecompound, an activator-support, and an organoaluminum compound, whereinno other materials are present in the catalyst composition which wouldincrease/decrease the activity of the catalyst composition by more thanabout 10% from the catalyst activity of the catalyst composition in theabsence of said materials.

This invention further encompasses methods of making these catalystcompositions, such as, for example, contacting the respective catalystcomponents in any order or sequence. In one embodiment, the catalystcomposition can be produced by a process comprising contacting theracemic ansa-bis(indenyl)zirconocene compound and the activator-support,while in another embodiment, the catalyst composition can be produced bya process comprising contacting, in any order, the racemicansa-bis(indenyl)zirconocene compound, the activator-support, and theco-catalyst, such as an organoaluminum compound.

Generally, the weight ratio of organoaluminum compound toactivator-support can be in a range from about 10:1 to about 1:1000. Ifmore than one organoaluminum compound and/or more than oneactivator-support are employed, this ratio is based on the total weightof each respective component. In another embodiment, the weight ratio ofthe organoaluminum compound to the activator-support can be in a rangefrom about 3:1 to about 1:100, or from about 1:1 to about 1:50.

In some embodiments of this invention, the weight ratio of metallocenecompound to activator-support can be in a range from about 1:1 to about1:1,000,000. If more than one metallocene compound and/or more thanactivator-support is/are employed, this ratio is based on the totalweights of the respective components. In another embodiment, this weightratio can be in a range from about 1:5 to about 1:100,000, or from about1:10 to about 1:10,000. Yet, in another embodiment, the weight ratio ofthe metallocene compound to the activator-support can be in a range fromabout 1:20 to about 1:1000.

Catalyst compositions of the present invention generally have a catalystactivity (or a catalyst productivity) of at least about 1,000 grams, atleast about 2,000 grams, at least about 3,500 grams, or at least about5,000 grams, and often can range up to about 10,000 grams, up to about15,000 grams, up to about 20,000 grams, or up to about 25,000 grams ofpolypropylene homopolymer per gram of activator-support per hour (orgrams of polypropylene homopolymer per gram of activator-support). Theseactivities (or productivities) are measured under bulk polymerizationconditions, with a triisobutylaluminum co-catalyst, a polymerizationtemperature of 77° C. and a reactor pressure of 520 psig (3.58 MPa).Additionally, in some embodiments, the activator-support can comprisesulfated alumina, fluorided silica-alumina, or fluorided silica-coatedalumina, although not limited thereto.

Additionally or alternatively, the disclosed catalyst compositions canhave a catalyst activity (or a catalyst productivity) of at least about250,000 grams, at least about 500,000 grams, at least about 1,000,000grams, or at least about 1,500,000 grams, and often can range up toabout 2,000,000 grams, up to about 3,000,000 grams, up to about4,000,000 grams, or up to about 5,000,000 grams of polypropylenehomopolymer per gram of metallocene compound per hour (or grams ofpolypropylene homopolymer per gram of metallocene compound). As above,these activities (or productivities) are measured under bulkpolymerization conditions, with a triisobutylaluminum co-catalyst, apolymerization temperature of 77° C. and a reactor pressure of 520 psig(3.58 MPa).

In circumstances where the metallocene compound comprises an alkenylsubstituent, the catalyst activity (or the catalyst productivity) of thecatalyst composition can be greater than that of a catalyst compositioncontaining a similar metallocene compound without the alkenylsubstituent, under the same polymerization conditions (bulkpolymerization conditions, with a triisobutylaluminum co-catalyst, 600molar ppm of H₂, a polymerization temperature of 77° C. and a reactorpressure of 520 psig (3.58 MPa)) and using the same catalyst preparationconditions and catalyst components (other than the metallocenecompound). Thus, the only difference is a metallocene compound with analkenyl substituent as compared to an otherwise identical metallocenecompound without the alkenyl substituent. In some embodiments, thecatalyst activity (or the catalyst productivity) of the catalystcomposition using the metallocene compound with the alkenyl substituentcan be at least about 10% greater, at least about 15% greater, or atleast about 25% greater, and often can range up to about 100%, or up toabout 200% greater, than that of a catalyst composition containing asimilar metallocene compound without the alkenyl substituent.

Polymerization Processes

The disclosed catalyst compositions can be used to polymerize propyleneto form a polypropylene homopolymer. One such polymerization process cancomprise contacting the catalyst composition with propylene in apolymerization reactor system under polymerization conditions to producethe polypropylene homopolymer. The polypropylene homopolymer can beproduced using any suitable olefin polymerization process using varioustypes of polymerization reactors, polymerization reactor systems, andpolymerization reaction conditions. As used herein, “polymerizationreactor” includes any polymerization reactor capable of polymerizingpropylene to produce a polypropylene homopolymer. The various types ofpolymerization reactors include, but are not limited to, those that canbe referred to as a batch reactor, slurry reactor, gas-phase reactor,solution reactor, high pressure reactor, tubular reactor, autoclavereactor, and the like, or combinations thereof. The polymerizationconditions for the various reactor types are well known to those ofskill in the art. Gas phase reactors can comprise fluidized bed reactorsor staged horizontal reactors. Slurry reactors can comprise vertical orhorizontal loops. High pressure reactors can comprise autoclavereactors, tubular reactors, or combinations thereof, in parallel or inseries. Reactor types can include batch or continuous processes.Continuous processes can use intermittent or continuous productdischarge. Polymerization reactor systems and processes also can includepartial or full direct recycle of unreacted monomer and diluent (ifused).

A polymerization reactor system can comprise a single reactor ormultiple reactors (for example, 2 reactors, or more than 2 reactors) ofthe same or different type. For instance, the polymerization reactorsystem can comprise a slurry reactor, a gas-phase reactor, a solutionreactor, or a combination of two or more of these reactors. Productionof polymers in multiple reactors can include several stages in at leasttwo separate polymerization reactors interconnected by at least onetransfer device making it possible to transfer the polymers resultingfrom the first polymerization reactor into the second reactor. Thedesired polymerization conditions in one of the reactors can bedifferent from the operating conditions of the other reactor(s).Alternatively, polymerization in multiple reactors can include themanual transfer of polymer from one reactor to subsequent reactors forcontinued polymerization. Multiple reactor systems can include anycombination including, but not limited to, multiple loop reactors,multiple gas phase reactors, a combination of loop and gas phasereactors, multiple high pressure reactors, or a combination of highpressure with loop or gas phase reactors. The multiple reactors can beoperated in series, in parallel, or both. For instance, a representativereactor system can include a loop reactor (one or more) in series with agas phase reactor (one or more).

According to one embodiment, the polymerization reactor system cancomprise at least one loop slurry reactor comprising vertical orhorizontal loops. Monomer, diluent (if used), catalyst, and comonomer(if used) can be continuously fed into a loop reactor wherepolymerization occurs. Generally, continuous processes can comprise thecontinuous introduction of monomer (and comonomer, if used), catalyst,and diluent (if used) into a polymerization reactor and the continuousremoval from this reactor of a suspension comprising polymer particlesand monomer or diluent. The wt. % solids in the loop reactor often canrange from about 30 wt. % to about 55 wt. %, or from about 40 wt. % toabout 70 wt. %. Reactor effluent can be flashed to remove the solidpolymer from the liquids that comprise the diluent (if used), monomer,and comonomer (if used). Various technologies can be used for thisseparation step including, but not limited to, flashing that can includeany combination of heat addition and pressure reduction, separation bycyclonic action in either a cyclone or hydrocyclone, or separation bycentrifugation.

A typical slurry polymerization process (also known as the particle formprocess) is disclosed, for example, in U.S. Pat. Nos. 3,248,179,4,501,885, 5,565,175, 5,575,979, 6,239,235, 6,262,191, 6,833,415, and8,822,608, each of which is incorporated herein by reference in itsentirety.

Suitable diluents used in slurry polymerization include, but are notlimited to, the monomer being polymerized and hydrocarbons that areliquids under reaction conditions. Examples of suitable diluentsinclude, but are not limited to, hydrocarbons such as propane,cyclohexane, isobutane, n-butane, n-pentane, isopentane, neopentane, andn-hexane. Some loop polymerization reactions can occur under bulkconditions where no diluent is used, such as can be employed in the bulkpolymerization of propylene to form polypropylene homopolymers.

According to yet another embodiment, the polymerization reactor systemcan comprise at least one gas phase reactor (e.g., a fluidized bedreactor). Such reactor systems can employ a continuous recycle streamcontaining one or more monomers continuously cycled through a fluidizedbed in the presence of the catalyst under polymerization conditions. Arecycle stream can be withdrawn from the fluidized bed and recycled backinto the reactor. Simultaneously, polymer product can be withdrawn fromthe reactor and new or fresh monomer can be added to replace thepolymerized monomer. Such gas phase reactors can comprise a process formulti-step gas-phase polymerization of olefins, in which olefins arepolymerized in the gaseous phase in at least two independent gas-phasepolymerization zones while feeding a catalyst-containing polymer formedin a first polymerization zone to a second polymerization zone. One typeof gas phase reactor is disclosed in U.S. Pat. Nos. 5,352,749,4,588,790, 5,436,304, 7,531,606, and 7,598,327, each of which isincorporated by reference in its entirety herein.

According to still another embodiment, the polymerization reactor systemcan comprise a high pressure polymerization reactor, e.g., can comprisea tubular reactor or an autoclave reactor. Tubular reactors can haveseveral zones where fresh monomer, initiators, or catalysts are added.Monomer can be entrained in an inert gaseous stream and introduced atone zone of the reactor. Initiators, catalysts, or catalyst componentscan be entrained in a gaseous stream and introduced at another zone ofthe reactor. The gas streams can be intermixed for polymerization. Heatand pressure can be employed appropriately to obtain optimalpolymerization reaction conditions.

According to yet another embodiment, the polymerization reactor systemcan comprise a solution polymerization reactor wherein themonomer/comonomer are contacted with the catalyst composition bysuitable stirring or other means. A carrier comprising an inert organicdiluent or excess monomer can be employed. If desired, themonomer/comonomer can be brought in the vapor phase into contact withthe catalytic reaction product, in the presence or absence of liquidmaterial. The polymerization zone can be maintained at temperatures andpressures that will result in the formation of a solution of the polymerin a reaction medium. Agitation can be employed to obtain bettertemperature control and to maintain uniform polymerization mixturesthroughout the polymerization zone. Adequate means are utilized fordissipating the exothermic heat of polymerization.

The polymerization reactor system can further comprise any combinationof at least one raw material feed system, at least one feed system forcatalyst or catalyst components, and at least one polymer recoverysystem. Suitable reactor systems can further comprise systems forfeedstock purification, catalyst storage and preparation, extrusion,reactor cooling, polymer recovery, fractionation, recycle, storage,loadout, laboratory analysis, and process control. Depending upon thedesired properties of the polypropylene homopolymer, hydrogen can beadded to the polymerization reactor as needed (e.g., continuously orpulsed) or as described herein.

Polymerization conditions that can be controlled for efficiency and toprovide desired polymer properties can include temperature, pressure,and the concentrations of various reactants. Polymerization temperaturecan affect catalyst productivity, polymer molecular weight, andmolecular weight distribution. Various polymerization conditions can beheld substantially constant, for example, for the production of aparticular grade of polypropylene homopolymer. A suitable polymerizationtemperature can be any temperature below the de-polymerizationtemperature according to the Gibbs Free energy equation. Typically, thisincludes from about 25° C. to about 280° C., for example, or from about25° C. to about 175° C., depending upon the type of polymerizationreactor. In some reactor systems, the polymerization temperaturegenerally can be within a range from about 60° C. to about 130° C., orfrom about 60° C. to about 95° C.

Suitable pressures will also vary according to the reactor andpolymerization type. The pressure for liquid phase polymerizations in aloop reactor typically can be less than 1000 psig (6.89 MPa). Thepressure for gas phase polymerization can be in the 200 psig (1.38 MPa)to 500 psig (3.45 MPa) range. High pressure polymerization in tubular orautoclave reactors generally can be conducted at about 20,000 psig(137.9 MPa) to 75,000 psig (517.1 MPa). Polymerization reactors also canbe operated in a supercritical region occurring at generally highertemperatures and pressures (for instance, above 92° C. and 700 psig(4.83 MPa)). Operation above the critical point of apressure/temperature diagram (supercritical phase) can offer advantagesto the polymerization reaction process.

Consistent with embodiments of this invention, the polymerizationprocesses are often conducted in the presence of H₂. For example, theprocess can be conducted in the presence of a molar amount of H₂, basedon propylene, ranging from about 100 ppm to about 2500 ppm, from about200 ppm to about 2000 ppm, or from about 300 ppm to about 1500 ppm H₂.These numbers are based on reactor contents under bulk polymerizationconditions.

Unexpectedly, and beneficially, the polypropylene melt flow rate (MFR)can increase dramatically with the addition of H₂ to the polymerizationprocess. For instance, the MFR can increase by from about 200% to about1000%, or from about 250% to about 900%, based on an increase in molarH₂ concentration (based on propylene) from 600 ppm to 1100 ppm. Alsounexpectedly, the ratio of Mw/Mn can be substantially constant (within+/−25%, and often within +/−15%) over a range of from 600 molar ppm H₂to 1000 molar ppm H₂. Thus, the polypropylenes produced by the processesdisclosed herein can have a flat or substantially constant ratio ofMw/Mn with increasing hydrogen concentration.

In circumstances where the metallocene compound comprises an alkenylsubstituent, the Mw/Mn of the polypropylene homopolymer produced by theprocess can be less (e.g., from about 5% to about 100% less, or fromabout 10% to about 75% less) than that of a homopolymer obtained using asimilar metallocene compound without the alkenyl substituent, under thesame polymerization conditions, and using the same catalyst preparationconditions and catalyst components (other than the metallocenecompound). The polymerization conditions can be bulk polymerizationconditions, with a triisobutylaluminum co-catalyst, 600 molar ppm of H₂,a polymerization temperature of 77° C. and a reactor pressure of 520psig (3.58 MPa). Thus, the only difference is a metallocene compoundwith an alkenyl substituent as compared to an otherwise identicalmetallocene compound without the alkenyl substituent.

This invention is also directed to, and encompasses, the polypropylenehomopolymers produced by any of the polymerization processes disclosedherein. Articles of manufacture (such as fibers and nonwoven articles)can be formed from, or can comprise, the homopolymers produced inaccordance with this invention.

EXAMPLES

The invention is further illustrated by the following examples, whichare not to be construed in any way as imposing limitations to the scopeof this invention. Various other aspects, embodiments, modifications,and equivalents thereof which, after reading the description herein, maysuggest themselves to one of ordinary skill in the art without departingfrom the spirit of the present invention or the scope of the appendedclaims.

Melt flow rate (MFR, g/10 min) was determined in accordance with ASTMD1238 at 230° C. with a 2,160 gram weight for lower melt flow ratepolypropylene resins (MFR less than 700 g/10 min). For higher melt flowrate polypropylene resins, dynamic frequency sweep measurement wereutilized. First, the polypropylene fluff sample was compression moldedat 182° C. for a total of 3 minutes. The samples were allowed to melt ata relatively low pressure for 1 minute, and then subjected to a highmolding pressure for an additional 2 minutes. The molded samples werethen quenched in a cold (room temperature) press, and then 25.4 mmdiameter disks were stamped out of the molded slabs for measurement in arotational rheometer.

The measurements were performed in parallel plates of 25 mm in diameterat 190° C. using a controlled-stress rheometer (Physica MCR-500, AntonPaar). The test chamber of the rheometer was purged with nitrogen tominimize oxidative degradation. After thermal equilibration, thespecimens were squeezed between the plates to a 1.0 mm thickness, andthe excess was trimmed. The dynamic frequency sweep test was performedwith 10% strain in the linear viscoelastic regime at angular frequenciesfrom 0.1 to 10 rad/s. The magnitudes of complex modulus |η*| were almostconstant in this frequency range. The average of the viscosities in thefrequency range of 0.1˜10 rad/s well represented the flow properties ofthe high MFR polypropylenes, and therefore, the average viscosity foreach high MFR sample was determined by calculating the average of 9viscosity measurements taken at approximately 0.1 rad/s, 0.178 rad/s,0.316 rad/s, 0.562 rad/s, 1 rad/s, 1.78 rad/s, 3.16 rad/s, 5.62 rad/s,and 10 rad/s.

The average viscosities (Pa-s) were then used to estimate the MFR (g/10min) using the following equation, which was determined from the powerlaw fit of the average viscosities of 3 high melt flow (500 g/10 min,1200 g/10 min, 1800 g/10 min, as determined by ASTM D1238) standardsamples: MFR=15,260 (viscosity)^(−0.903). The plot correlating MFR toaverage viscosity is illustrated in FIG. 1.

Molecular weights and molecular weight distribution curves were obtainedusing a PL-GPC 220 (Polymer Labs, an Agilent Company) system equippedwith a IR4 detector (Polymer Char, Spain) and three Styragel HMW-6E GPCcolumns (Waters, Mass.) running at 145° C. The flow rate of the mobilephase 1,2,4-trichlorobenzene (TCB) containing 0.5 g/L2,6-di-t-butyl-4-methylphenol (BHT) was set at 1 mL/min, and polymersolution concentrations were in the range of 1.0-1.5 mg/mL, depending onthe molecular weight. Sample preparation was conducted at 150° C. fornominally 4 hr with occasional and gentle agitation, before thesolutions were transferred to sample vials for injection. An injectionvolume of about 400 μL was used. The integral calibration method wasused to deduce molecular weights and molecular weight distributionsusing a Chevron Phillips Chemical Company's HDPE polyethylene resin,MARLEX® BHB5003, as the broad standard. The integral table of thestandard was pre-determined in a separate experiment with SEC-MALS. Mnis the number-average molecular weight, Mw is the weight-averagemolecular weight, Mz is the z-average molecular weight, and Mp is thepeak molecular weight (location, in molecular weight, of the highestpoint of the molecular weight distribution curve).

The peak melting point (Tm) was determined using Differential ScanningCalorimetry (DSC) as described in ASTM D3418 (2nd heat, ° C.) at aheating rate of 10° C./min.

Triad determination and the tacticity of the polypropylene homopolymerwere determined utilizing ¹³C NMR peak intensities and the methods asdescribed in Zambelli, A.; Locatelli, P.; Bajo, G.; Bovey, F. A.;Macromolecules, 1975, 8 (5), 687-689.

Fluorided silica-coated alumina activator-supports were prepared asfollows. Bohemite was obtained from W.R. Grace & Company under thedesignation “Alumina A” and having a surface area of about 300 m²/g, apore volume of about 1.3 mL/g, and an average particle size of about 100microns. The alumina was first calcined in dry air at about 600° C. forapproximately 6 hours, cooled to ambient temperature, and then contactedwith tetraethylorthosilicate in isopropanol to equal 25 wt. % SiO₂.After drying, the silica-coated alumina was calcined at 600° C. for 3hours. Fluorided silica-coated alumina (7 wt. % F) was prepared byimpregnating the calcined silica-coated alumina with an ammoniumbifluoride solution in methanol, drying, and then calcining for 3 hoursat 600° C. in dry air. Afterward, the fluorided silica-coated alumina(FSCA) was collected and stored under dry nitrogen, and was used withoutexposure to the atmosphere.

The structures of the racemic ansa-bis(indenyl)zirconocene compounds (A,B, C, D, E) used in Examples 1-105 are shown below:

Examples 1-108

Examples 1-77 were performed in a 1-gallon autoclave reactor, usingtriisobutylaluminum (TIBA) purchased from Sigma-Aldrich as a 1.0 Msolution in heptane, and fluorided silica-coated alumina (FSCA) as theactivator-support. Table I summarizes the polymerization conditions usedfor Examples 1-77, with variations in the hydrogen addition methodprovided below.

For Method N (no hydrogen added), the metallocene compound, FSCA, andTIBA were charged to a syringe and slurried in hexanes. The catalystsystem slurry was charged to the 1-gallon reactor under a nitrogenstream. The reactor was sealed and charged with 2.5 L of liquidpropylene. The reactor was stirred at 1000 rpm, heated to 77° C.(pressure of approximately 520 psig (3.58 MPa)), and held for theindicated reaction time before venting and recovering the polypropyleneresin.

For Method A1 (hydrogen addition at beginning), the metallocenecompound, FSCA, and TIBA were charged to a syringe and slurried inhexanes. The catalyst system slurry was charged to the 1-gallon reactorunder a nitrogen stream. The reactor was sealed and charged with 2.5 Lof liquid propylene, followed by the designated amount of hydrogen. Thereactor was stirred at 1000 rpm, heated to 77° C. (pressure ofapproximately 520 psig (3.58 MPa)), and held for the indicated reactiontime before venting and recovering the polypropylene resin.

For Method B2 (continuous hydrogen addition), the metallocene compound,FSCA, and TIBA were charged to a syringe and slurried in hexanes. Thecatalyst system slurry was charged to the 1-gallon reactor under anitrogen stream. The reactor was sealed and charged with 2.5 L of liquidpropylene, followed by the designated amount of hydrogen. The reactorwas stirred at 1000 rpm and heated to 77° C. (pressure of approximately520 psig (3.58 MPa)). The designated amount of hydrogen was continuouslyfed to the reactor over the reaction time, after which the reactor wasvented and the polypropylene resin was recovered.

For Method C3 (hydrogen addition at beginning, higher temperature), themetallocene compound, FSCA, and TIBA were charged to a syringe andslurried in hexanes. The catalyst system slurry was charged to the1-gallon reactor under a nitrogen stream. The reactor was sealed,charged with 2.5 L of liquid propylene, and heated to 60° C. whilestirring at 1000 rpm. The designated amount of hydrogen was fed to thereactor, and the reactor was then heated to 77° C. After the indicatedreaction time, the reactor was vented and the polypropylene resin wasrecovered.

For Method D4 (hydrogen addition at beginning, higher temperature), themetallocene compound, FSCA, and TIBA were charged to a syringe andslurried in hexanes. The catalyst system slurry was charged to the1-gallon reactor under a nitrogen stream. The reactor was sealed,charged with 2.5 L of liquid propylene, and heated to 65° C. whilestirring at 1000 rpm. The designated amount of hydrogen was fed to thereactor, and the reactor was then heated to 77° C. After the indicatedreaction time, the reactor was vented and the polypropylene resin wasrecovered.

For Method E5 (first charge, second continuous), the metallocenecompound, FSCA, and TIBA were charged to a syringe and slurried inhexanes. The catalyst system slurry was charged to the 1-gallon reactorunder a nitrogen stream. The reactor was sealed, charged with 2.5 L ofliquid propylene, and heated to 60° C. while stirring at 1000 rpm. Thefirst designated amount of hydrogen was fed to the reactor, and thereactor was then heated to 77° C. The second designated amount ofhydrogen was continuously fed to the reactor over the reaction time,after which the reactor was vented and the polypropylene resin wasrecovered.

Examples 78-106 were performed in a 5-gallon reactor, but in a similarmanner to Examples 1-77, and with hydrogen addition methods as describedabove for Examples 1-77. Table III summarizes the polymerizationconditions used for Examples 78-106, with variations in the hydrogenaddition method provided in the table as discussed above. Table II andTable IV summarize the catalyst performance (activity and productivity)and polymer properties of Examples 1-77 and Examples 78-106,respectively.

As shown by Examples 1-7 in Tables I-II, catalyst systems containingmetallocene compounds B and C produced polymers with slightly broaderMWDs (larger Mw/Mn ratios) than catalyst systems containing metallocenecompounds D and E, which have alkenyl substituents. Examples 8-20 ascompared to Examples 21-37 demonstrate the effect of adding hydrogen atelevated temperature. In general, there was no significant difference inMWD with metallocene compound B when hydrogen was added at 60° C. versusat ambient temperature.

Examples 21-55 demonstrate the unique and unexpected performance ofmetallocene compound D, with an alkenyl substituent on the bridgingatom, as compared to a saturated analog (metallocene compound C) and asymmetric silyl bridging group (metallocene B). In the absence ofhydrogen, the productivities of metallocene compounds C and D werenearly identical, and lower than that of metallocene compound B.However, as shown in FIG. 2, in the presence of hydrogen, metallocenecompound D (with the alkenyl substituent as part of the silyl bridginggroup) was surprisingly more productive than metallocene compounds B andC. In addition, FIG. 2 illustrates the increased hydrogen response ofmetallocene compound D. In fact, it appears that with respect toproductivity, metallocene compounds B and C have similar hydrogenresponses (accounting for the productivity offset), while the responseof metallocene compound D to hydrogen (different shape of curve) differsfrom either that of metallocene compounds B or C. FIG. 2 uses data fromExamples 2, 5, 6, 23, 25, 26, 38, 39, 41, and 42, and the H₂concentration is in molar ppm based on propylene.

The melt flow rate (MFR) responses of metallocene compounds C and D weresimilar at low hydrogen concentration, as shown in FIG. 3. However, andbeneficially, the melt flow rate response of metallocene compound D atincreased hydrogen concentration was greater than that of metallocenecompound C, indicating the unexpected impact of the alkenyl substituenton polypropylene molecular weight. Metallocene compound C trended moreclosely with metallocene compound B at high hydrogen concentration,while metallocene compound D exhibited a much stronger hydrogen responsewith respect to MFR. FIG. 3 uses data from Examples 2, 5, 6, 23, 25, 26,38, 39, 41, and 42, and the H₂ concentration is in molar ppm based onpropylene.

FIG. 4 demonstrates the narrower MWDs of polypropylenes produced usingmetallocene compound D (versus metallocene compounds B and C), as wellas the surprisingly flat impact of the hydrogen concentration on theMWD. FIG. 4 uses data from Example 2, 5, 6, 23, 25, 26, 38, 39, 41, and42, and the H₂ concentration is in molar ppm based on propylene.

Examples 56-64 in Tables I-II utilized a single front end drop ofhydrogen at elevated temperature (60° C.). Generally, these examplesdemonstrate that the productivity of the alkenyl-containing metallocenecompounds was superior to that of the other metallocenes, and that thealkenyl-containing metallocene compounds resulted in narrower MWDs.Examples 65-72 were similar to those of Examples 56-64, except that thehydrogen addition temperature was increased to 65° C. The results werevery similar, except that the MWD narrowing was less significant for thealkenyl-containing metallocene compound. Examples 73-77 attempted tooffset hydrogen consumption during the polymerization and to maintainconstant hydrogen concentration: an initial hydrogen charge was added at60° C., and a constant hydrogen feed was maintained through remainder ofrun. As above, the MWDs of polypropylenes produced usingalkenyl-substituted metallocene compounds were significantly lower thanpolypropylene produced with the other metallocene compounds, despite themore constant hydrogen concentrations.

Examples 78-106 in Tables III-IV produced low molecular weightpolypropylenes, and similar to the other examples, the MWDs ofpolypropylenes produced using alkenyl-substituted metallocene compoundswere typically lower than polypropylenes produced with the othermetallocene compounds.

Tables I-IV demonstrate that polypropylene homopolymers with melt flowrates ranging from 200 g/10 min to 3000 g/10 min, ratios of Mw/Mnranging from 2 to 5, and ratios of Mz/Mw ranging from 1.7 to 3.5 can beproduced using a variety of catalyst systems and under a variety ofpolymerization reaction conditions. Moreover, the catalyst systems hadunexpectedly high metallocene catalyst activities (grams of polymer pergram of metallocene per hour, g/g/hr) and catalyst productivities (gramsof polymer per gram of metallocene, g/g): generally from 500,000 g/g/hrto almost 4,000,000 g/g/hr, and generally from 250,000 g/g to over2,000,000 g/g. Likewise, the catalyst systems had unexpectedly highcatalyst activities based on the activator-support (grams of polymer pergram of activator-support per hour, g/g/hr) and catalyst productivities(grams of polymer per gram of activator-support, g/g): generally from2,000 g/g/hr to almost 20,000 g/g/hr, and generally from 1,000 g/g toover 10,000 g/g.

Due to the high catalyst activities and catalyst productivities, theresulting polypropylene homopolymer can have very low levels of catalystresidue. For instance, the zirconium content (in parts per billion, ppb,by weight) in Examples 100-106 was calculated by multiplying the μmol Zrcharged to the reactor times the molar mass of Zr times 1000, and thendividing by the grams of polymer produced in each example (seemetallocene productivity values in Table IV). Thus, for Example 100, 1mg of metallocene E was used, corresponding to 1.3 μmol of zirconium,and therefore (1.3*91.22*1000)/1652 results in approximately 72 ppb ofzirconium in the polypropylene homopolymer of Example 100. For thepolypropylene homopolymers of Examples 100-106, the ppb zirconiumcontents ranged from 58 ppb to 108 ppb.

Table V summarizes the polymer properties for Examples 107-108. Example107 was a commercially-available polypropylene homopolymer resin fromExxon having a nominal MFR of 1500 g/10 min, while Example 108 was acommercially-available polypropylene homopolymer resin fromLyondell/Basell having a nominal MFR of 1200 g/10 min. Table VI comparesthe DSC peak melting points for representative polypropylenehomopolymers of this invention with those of comparative Examples107-108. Unexpectedly, the polypropylene homopolymers disclosed hereinhad surprisingly lower peak melting points, ranging from 139° C. to 150°C. Despite the lower melting points, the polypropylene homopolymersdisclosed herein had similar isotactic contents ([mm], % isotactic atthe triad level) to those of Examples 107-108, as shown in Table VII.

TABLE I Examples 1-77 - Polymerization reaction conditions. H₂ InitialInitial Metered Metered Total H₂ Metallocene FSCA TIBA addition H₂ dropH₂ drop H₂ drop H₂ drop Total (ppm, Time Example Metallocene (μmol) (mg)(mmol) method (mg) (psi) (mg) (psi) H₂ (mg) μmol/mol) (hr) 1 B 0.4 500.5 N 0 0 0 0 0 0 0.5 2 B 0.4 100 0.5 N 0 0 0 0 0 0 0.5 3 B 0.4 150 0.5N 0 0 0 0 0 0 0.5 4 B 0.4 200 0.5 N 0 0 0 0 0 0 0.5 5 C 0.37 50 0.5 N 00 0 0 0 0 0.5 6 D 0.37 50 0.5 N 0 0 0 0 0 0 0.5 7 E 0.32 50 0.5 N 0 0 00 0 0 0.5 8 B 0.4 125 0.5 A1 34 20 NA NA 34 556 0.5 9 B 0.4 125 0.5 A134 20 NA NA 34 556 0.5 10 B 0.4 125 0.5 A1 67 40 NA NA 67 1113 0.5 11 B0.4 100 0.5 A1 101 60 NA NA 101 1669 0.5 12 B 0.4 100 0.5 A1 135 80 NANA 135 2226 0.5 13 B 0.4 100 0.5 A1 135 80 NA NA 135 2226 0.5 14 B 0.4100 0.5 A1 168 100 NA NA 168 2782 0.5 15 B 0.4 100 0.5 A1 34 20 NA NA 34556 0.5 16 B 0.4 100 0.5 A1 168 100 NA NA 168 2782 0.5 17 B 0.8 100 0.5A1 34 20 NA NA 34 556 0.5 18 B 0.8 100 0.5 A1 34 20 NA NA 34 556 0.5 19B 0.8 100 0.5 A1 34 20 NA NA 34 556 0.5 20 B 0.8 100 0.5 A1 34 20 NA NA34 556 0.5 21 B 0.8 50 0.5 B2 17 10 0 0 17 278 0.5 22 B 0.4 50 0.5 B2 3420 0 0 34 556 0.5 23 B 0.4 50 0.5 B2 17 10 13 8 30 501 0.5 24 B 0.4 500.5 B2 17 10 34 20 50 835 0.5 25 B 0.4 50 0.5 B2 17 10 32 19 49 807 0.526 B 0.4 50 0.5 B2 17 10 40 24 57 946 0.5 27 B 0.4 50 0.5 B2 34 20 13 847 779 0.5 28 B 0.4 50 0.5 B2 34 20 27 16 61 1002 0.5 29 B 0.4 50 0.5 B250 30 17 10 67 1113 0.5 30 B 0.4 50 0.5 B2 50 30 15 9 66 1085 0.5 31 B0.4 50 0.5 B2 50 30 32 19 82 1363 0.5 32 B 0.4 50 0.5 B2 67 40 17 10 841391 0.5 33 B 0.4 50 0.5 B2 67 40 30 18 98 1614 0.5 34 B 0.4 50 0.5 B250 30 13 8 64 1057 0.5 35 B 0.4 50 0.5 B2 67 40 50 30 118 1947 0.5 36 B0.4 50 0.5 B2 50 30 34 20 84 1391 0.5 37 B 0.4 50 0.5 B2 50 30 0 0 50835 0.5 38 C 0.37 50 0.5 B2 17 10 17 10 34 556 0.5 39 C 0.37 50 0.5 B217 10 50 30 67 1113 0.5 40 C 0.37 50 0.5 B2 17 10 50 30 67 1113 1 41 D0.37 50 0.5 B2 17 10 17 10 34 556 0.5 42 D 0.37 50 0.5 B2 17 10 45 27 621029 0.5 43 D 0.22 30 0.4 B2 34 20 17 10 50 835 0.5 44 D 0.22 30 0.4 B234 20 27 16 61 1002 0.5 45 D 0.22 30 0.4 B2 34 20 62 37 96 1586 0.5 46 D0.22 30 0.4 B2 50 30 17 10 67 1113 0.5 47 D 0.22 30 0.4 B2 50 30 34 2084 1391 0.5 48 D 0.22 30 0.4 B2 67 40 17 10 84 1391 0.5 49 D 0.22 30 0.4B2 67 40 17 10 84 1391 0.5 50 D 0.22 30 0.4 B2 50 30 27 16 77 1280 0.551 D 0.22 30 0.4 B2 50 30 32 19 82 1363 0.5 52 D 0.22 30 0.4 B2 67 40 3420 101 1669 0.5 53 D 0.22 30 0.4 B2 67 40 50 30 118 1947 0.5 54 D 0.2230 0.4 B2 50 30 64 38 114 1892 1 55 D 0.22 30 0.4 B2 50 30 34 20 84 13911 56 B 0.4 50 0.5 C3 34 20 NA NA 34 556 0.5 57 C 0.37 50 0.5 C3 34 20 NANA 34 556 0.5 58 D 0.37 50 0.5 C3 34 20 NA NA 34 556 0.5 59 E 0.32 500.5 C3 17 10 NA NA 17 278 0.5 60 E 0.32 50 0.5 C3 34 20 NA NA 34 556 0.561 E 0.32 100 0.5 C3 34 20 NA NA 34 556 0.5 62 E 0.19 30 0.5 C3 50 30 NANA 50 835 0.5 63 E 0.19 30 0.5 C3 67 40 NA NA 67 1113 0.5 64 E 0.19 300.5 C3 67 40 NA NA 67 1113 0.5 65 B 0.4 50 0.5 D4 67 40 67 NA 67 11130.5 66 B 0.4 50 0.5 D4 34 20 34 NA 34 556 1 67 C 0.37 50 0.5 D4 34 20 34NA 34 556 0.5 68 C 0.37 50 0.5 D4 67 40 67 NA 67 1113 0.5 69 C 0.37 500.5 D4 34 20 34 NA 34 556 1 70 D 0.37 50 0.5 D4 34 20 34 NA 34 556 0.571 D 0.37 50 0.5 D4 67 40 67 NA 67 1113 0.5 72 D 0.37 50 0.5 D4 34 20 34NA 34 556 1 73 B 0.24 30 0.4 E5 50 30 34 20 84 1391 1 74 D 0.22 30 0.4E5 50 30 34 20 84 1391 1 75 E 0.19 30 0.5 E5 34 20 32 19 66 1085 0.5 76E 0.19 30 0.5 E5 34 20 27 16 61 1002 1 77 E 0.19 30 0.5 E5 50 30 32 1982 1363 1

TABLE II Examples 1-77—Polymer properties and catalyst performance.Metallocene Metallocene Support Support Productivity Activityproductivity Activity MFR Mn Mw Mz Tm Example (g/g) (g/g/hr) (g/g)(g/g/hr) (g/10 min) (kg/mol) (kg/mol) (kg/mol) Mw/Mn Mz/Mw (° C.) 1124,000 248,000 620 1,240 0 346 912 1719 2.6 1.9 2 176,000 352,000 440880 0 345 885 1661 2.6 1.9 3 184,000 368,000 307 614 0 333 857 1631 2.61.9 4 180,000 360,000 225 450 325 833 1526 2.6 1.8 5 52,000 104,000 260520 0 323 933 1823 2.9 2.0 6 56,000 112,000 280 560 0 289 722 1373 2.51.9 7 48,000 96,000 240 480 0 347 843 1628 2.4 1.9 8 1,084,000 2,168,0002,168 4,336 19 63 206 377 3.3 1.8 9 784,000 1,568,000 1,568 3,136 15 66219 405 3.3 1.8 10 884,000 1,768,000 1,768 3,536 277 27 101 204 3.7 2.011 1,036,000 2,072,000 2,590 5,180 200 25 105 217 4.2 2.1 12 180,000360,000 450 900 13 1,132,000 2,264,000 2,830 5,660 1557 13 54 131 4.22.4 148.2 14 880,000 1,760,000 2,200 4,400 1686 12 50 121 4.3 2.4 15780,000 1,560,000 1,950 3,900 40 63 198 364 3.1 1.8 16 952,000 1,904,0002,380 4,760 960 6 62 462 10.1 7.5 17 452,000 904,000 2,260 4,520 27 18838,000 1,676,000 4,190 8,380 72 239 434 3.3 1.8 19 110,000 220,000 5501,100 20 32 222 549 6.9 2.5 20 712,000 1,424,000 3,560 7,120 13 57 218405 3.8 1.9 21 636,000 1,272,000 6,360 12,720 5 22 652,000 1,304,0003,260 6,520 32 54 178 327 3.3 1.8 23 904,000 1,808,000 4,520 9,040 4 89275 496 3.1 1.8 149.3 24 904,000 1,808,000 4,520 9,040 21 52 188 369 3.62.0 25 1,040,000 2,080,000 5,200 10,400 19 50 200 422 4.0 2.1 261,008,000 2,016,000 5,040 10,080 53 42 156 311 3.7 2.0 27 748,0001,496,000 3,740 7,480 22 53 185 347 3.5 1.9 28 1,060,000 2,120,000 5,30010,600 53 44 152 296 3.5 1.9 29 556,000 1,112,000 2,780 5,560 70 37 146292 4.0 2.0 30 532,000 1,064,000 2,660 5,320 442 25 103 228 4.2 2.2 31972,000 1,944,000 4,860 9,720 273 26 104 217 4.0 2.1 32 1,084,0002,168,000 5,420 10,840 397 25 96 197 3.9 2.1 33 996,000 1,992,000 4,9809,960 377 23 94 198 4.1 2.1 34 844,000 1,688,000 4,220 8,440 100 34 125242 3.7 1.9 35 844,000 1,688,000 4,220 8,440 18 71 160 4.0 2.2 36752,000 1,504,000 3,760 7,520 298 27 93 189 3.5 2.0 37 852,000 1,704,0004,260 8,520 180 25 102 203 4.1 2.0 38 688,000 1,376,000 3,440 6,880 2052 187 364 3.6 1.9 39 672,000 1,344,000 3,360 6,720 105 27 134 317 5.02.4 40 584,000 584,000 2,920 2,920 73 28 141 356 5.1 2.5 41 1,100,0002,200,000 5,500 11,000 24 69 179 323 2.6 1.8 42 1,424,000 2,848,0007,120 14,240 143 45 114 230 2.6 2.0 43 1,413,333 2,826,667 7,067 14,133100 47 116 213 2.5 1.8 44 1,406,667 2,813,333 7,033 14,067 98 45 121 2342.7 1.9 45 1,873,333 3,746,667 9,367 18,733 482 29 81 168 2.8 2.1 461,140,000 2,280,000 5,700 11,400 359 34 87 169 2.5 1.9 47 1,146,6672,293,333 5,733 11,467 1063 23 63 123 2.8 1.9 48 740,000 1,480,000 3,7007,400 26 72 139 2.8 1.9 49 1,666,667 3,333,333 8,333 16,667 465 28 78149 2.7 1.9 50 1,000,000 2,000,000 5,000 10,000 760 26 74 153 2.9 2.1 511,413,333 2,826,667 7,067 14,133 895 27 68 129 2.5 1.9 52 1,066,6672,133,333 5,333 10,667 2049 20 55 112 2.8 2.0 53 1,153,333 2,306,6675,767 11,533 3600 15 42 86 2.9 2.0 54 1,946,667 1,946,667 9,733 9,733696 20 70 153 3.5 2.2 55 1,573,333 1,573,333 7,867 7,867 1442 20 61 1273.1 2.1 146.1 56 476,000 952,000 2,380 4,760 34 47 168 331 3.6 2.0 57720,000 1,440,000 3,600 7,200 25 56 180 333 3.2 1.8 58 964,000 1,928,0004,820 9,640 113 43 123 239 2.9 1.9 59 764,000 1,528,000 3,820 7,640 9 94265 505 2.8 1.9 148.8 60 1,228,000 2,456,000 6,140 12,280 83 47 138 2732.9 2.0 61 1,636,000 3,272,000 4,090 8,180 16 69 212 413 3.1 1.9 621,153,333 2,306,667 5,767 11,533 776 26 79 170 3.1 2.2 63 1,233,3332,466,667 6,167 12,333 1447 21 64 135 3.1 2.1 148.8 64 1,626,6673,253,333 8,133 16,267 1433 19 60 131 3.1 2.2 65 1,032,000 2,064,0005,160 10,320 533 22 82 177 3.7 2.2 66 1,632,000 1,632,000 8,160 8,160 1271 224 402 3.1 1.8 67 756,000 1,512,000 3,780 7,560 41 48 158 297 3.31.9 68 940,000 1,880,000 4,700 9,400 645 18 76 167 4.2 2.2 148.1 691,452,000 1,452,000 7,260 7,260 10 75 230 407 3.1 1.8 70 1,064,0002,128,000 5,320 10,640 218 36 109 215 3.0 2.0 71 1,304,000 2,608,0006,520 13,040 16 59 133 3.7 2.3 72 1,568,000 1,568,000 7,840 7,840 66 49147 285 3.0 1.9 73 1,146,667 1,146,667 5,733 5,733 20 80 172 4.0 2.1 742,193,333 2,193,333 10,967 10,967 21 66 130 3.1 2.0 75 1,260,0002,520,000 6,300 12,600 25 78 168 3.1 2.1 148.6 76 1,746,667 1,746,6678,733 8,733 23 75 159 3.2 2.1 77 1,606,667 1,606,667 8,033 8,033 18 56126 3.1 2.2

TABLE III Examples 78-106 - Polymerization reaction conditions. H₂Initial Initial Metered Metered Total H₂ Metallocene FSCA TIBA additionH₂ drop H₂ drop H₂ drop H₂ drop Total (ppm, Time Example Metallocene(μmol) (mg) (mmol) method (mg) (psi) (mg) (psi) H₂ (mg) μmol/mol) (hr)78 A 6.3 1200 1 A1 0 NA NA 0 0 0.75 79 A 6.3 1200 2 A1 0 NA NA 0 0 0.7580 A 6.3 1200 2 A1 1122 NA NA 1122 4116 0.75 81 A 6.3 1200 2 A1 2243 NANA 2243 8233 0.75 82 A 6.3 1200 2 A1 1122 NA NA 1122 4116 0.75 83 A 6.31200 2 A1 0 NA NA 0 0 0.75 84 A 6.3 1200 2 A1 561 NA NA 561 2058 0.75 85A 6.3 1200 2 A1 393 NA NA 393 1441 0.75 86 A 6.3 1200 2 A1 449 NA NA 4491647 0.75 87 A 6.3 1200 2 A1 505 NA NA 505 1852 0.75 88 A 6.3 900 2 A1561 NA NA 561 2058 0.75 89 A 6.3 900 2 A1 505 NA NA 505 1852 0.75 90 A4.2 600 2 A1 505 NA NA 505 1852 0.75 91 A 4.2 600 2 505 NA NA 505 18520.75 92 B 3.2 800 2 A1 393 70 NA NA 393 1441 0.5 93 B 3.2 400 2 A1 39370 NA NA 393 1441 0.5 94 B 2.4 300 1.5 A1 449 80 NA NA 449 1647 0.5 95 B2.4 300 2 A1 449 80 NA NA 449 1647 0.5 96 E 1.9 300 1.5 C3 280 50 NA NA280 1029 0.5 97 E 1.9 300 1.5 C3 336 60 NA NA 336 1235 0.5 98 E 1.3 2001.5 C3 336 60 NA NA 336 1235 1 99 E 1.3 200 1.5 C3 393 70 NA NA 393 14410.5 100 E 1.3 200 1.5 E5 336 60 84 15 421 1544 1 101 E 1.3 200 1.5 E5280 50 84 15 365 1338 1 102 E 1.3 200 1.5 E5 280 50 140 25 421 1544 1103 E 1.3 200 1.5 E5 336 60 56 10 393 1441 1 104 E 1.3 200 1.5 E5 336 60112 20 449 1647 1 105 E 1.3 200 1.5 E5 336 60 112 20 449 1647 1 106 E1.3 200 1.5 E5 308 55 140 25 449 1647 1

TABLE IV Examples 78-106 - Polymer properties and catalyst performance.Metallocene Metallocene Support Support Productivity Activityproductivity Activity MFR Mn Mw Mz Tm Example (g/g) (g/g/hr) (g/g)(g/g/hr) (g/10 min) (kg/mol) (kg/mol) (kg/mol) Mw/Mn Mz/Mw (° C.) 78116,667 155,556 292 389 91 40 138 286 3.5 2.1 79 435,667 580,889 1,0891,452 28 42 132 256 3.2 1.9 80 408,000 544,000 1,020 1,360 29 6 18 402.8 2.3 81 778,667 1,038,222 1,947 2,596 16 4 13 46 3.4 3.5 82 568,667758,222 1,422 1,896 6 19 58 3.2 3.1 83 675,333 900,444 1,688 2,251 753NA NA NA NA NA 84 744,667 992,889 1,862 2,482 1618 16 60 167 3.8 2.8 85744,667 992,889 1,862 2,482 1435 19 62 143 3.3 2.3 142.0 86 652,000869,333 1,630 2,173 3054 13 41 96 3.2 2.3 139.8 87 541,000 721,333 1,3531,803 7001 13 39 85 3.0 2.2 140.9 88 721,000 961,333 2,403 3,204 3125 1758 148 3.5 2.5 141.1 89 754,333 1,005,778 2,514 3,353 1415 17 65 172 3.82.6 140.9 90 751,500 1,002,000 2,505 3,340 4671 14 47 123 3.4 2.6 141.191 557,000 742,667 1,857 2,476 12 38 90 3.3 2.4 141.8 92 1,315,0002,630,000 3,288 6,575 82 34 156 427 4.6 2.7 93 1,180,000 2,360,000 5,90011,800 177 34 134 273 3.9 2.0 94 760,000 1,520,000 3,800 7,600 30 119248 4.0 2.1 95 562,000 1,124,000 2,810 5,620 19 73 158 3.9 2.2 961,111,333 2,222,667 5,557 11,113 646 26 76 150 2.9 2.0 97 1,332,0002,664,000 6,660 13,320 211 38 105 211 2.8 2.0 98 2,051,000 2,051,00010,255 10,255 443 29 88 181 2.8 2.0 99 1,865,000 3,730,000 9,325 18,650100 1,652,000 1,652,000 8,260 8,260 1088 23 68 139 2.9 2.0 101 1,783,0001,783,000 8,915 8,915 838 25 75 160 3.0 2.1 102 2,024,000 2,024,00010,120 10,120 880 24 68 134 2.8 2.0 103 2,013,000 2,013,000 10,06510,065 792 24 76 164 3.1 2.2 104 1,100,000 1,100,000 5,500 5,500 1517 2162 130 2.9 2.1 105 1,454,000 1,454,000 7,270 7,270 20 58 114 2.9 2.0 1061,490,000 1,490,000 7,450 7,450 1674 18 56 119 3.1 2.1 148.6

TABLE V Examples 107-108 - Polymer properties of comparativepolypropylene homopolymers. MFR Mn Mw Mz (g/ (kg/ (kg/ (kg/ Tm Example10 min) mol) mol) mol) Mw/Mn Mz/Mw (° C.) 107 1500 26 60 102 2.3 1.7152.3 108 1200 22 68 128 3.1 1.9 153.7

TABLE VI DSC peak melting points. MFR Tm Example (g/10 min) (° C.) 131557 148.2 23 4.1 149.3 55 1442 146.1 59 8.9 148.8 63 1447 148.8 68 645148.1 75 148.6 85 1435 142.0 86 3054 139.8 87 7001 140.9 88 3125 141.189 1415 140.9 90 4671 141.1 91 141.8 107 1500 152.3 108 1200 153.7

TABLE VII Tacticity analysis. Isotatic Syndiotactic Atactic [mm] [rr][mr] Example (%) (%) (%) 13 96.9 0.7 2.4 55 96.6 0.7 2.7 63 97.2 0.6 2.268 97.2 0.6 2.2 89 93.0 2.1 4.9 106 96.2 3.0 0.8 107 97.0 2.3 0.7 10899.1 0.7 0.3

The invention is described above with reference to numerous aspects andembodiments, and specific examples. Many variations will suggestthemselves to those skilled in the art in light of the above detaileddescription. All such obvious variations are within the full intendedscope of the appended claims. Other embodiments of the invention caninclude, but are not limited to, the following (embodiments aredescribed as “comprising” but, alternatively, can “consist essentiallyof” or “consist of”):

Embodiment 1

A polypropylene homopolymer having a melt flow rate in a range fromabout 200 g/10 min to about 3000 g/10 min, a ratio of Mw/Mn in a rangefrom about 2 to about 5, and a peak melting point in a range from about138° C. to about 151° C.

Embodiment 2

A polypropylene homopolymer having a melt flow rate in a range fromabout 200 g/10 min to about 3000 g/10 min, a ratio of Mw/Mn in a rangefrom about 2 to about 5, and a ratio of Mz/Mw in a range from about 1.7to about 3.5.

Embodiment 3

The homopolymer defined in embodiment 1 or 2, wherein the homopolymerhas a melt flow rate in any range disclosed herein, e.g., from about 300g/10 min to about 2500 g/10 min, from about 350 g/10 min to about 2500g/10 min, from about 500 g/10 min to about 2500 g/10 min, or from about500 g/10 min to about 2000 g/10 min.

Embodiment 4

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a ratio of Mw/Mn in any range disclosed herein,e.g., from about 2.2 to about 5, from about 2.2 to about 4.5, from about2.4 to about 5, or from about 2.4 to about 4.5.

Embodiment 5

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a ratio of Mz/Mw in any range disclosed herein,e.g., from about 1.7 to about 3, from about 1.8 to about 3.5, from about1.8 to about 3, or from about 1.9 to about 2.8.

Embodiment 6

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a peak melting point in any range disclosed herein,e.g., from about 138° C. to about 152° C., from about 140° C. to about150° C., or from about 141° C. to about 149° C.

Embodiment 7

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has an isotacticity [mm] in any range disclosed herein,e.g., from about 93% to about 99%, from about 94% to about 98%, or fromabout 96% to about 98%.

Embodiment 8

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a Mw in any range disclosed herein, e.g., from about40,000 g/mol to about 110,000 g/mol, from about 40,000 g/mol to about90,000 g/mol, from about 45,000 g/mol to about 110,000 g/mol, or fromabout 45,000 g/mol to about 85,000 g/mol.

Embodiment 9

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a Mn in any range disclosed herein, e.g., from about10,000 g/mol to about 40,000 g/mol, from about 10,000 g/mol to about30,000 g/mol, from about 12,000 g/mol to about 35,000 g/mol, or fromabout 12,000 g/mol to about 28,000 g/mol.

Embodiment 10

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer has a Mz in any range disclosed herein, e.g., from about80,000 g/mol to about 230,000 g/mol, from about 90,000 g/mol to about200,000 g/mol, from about 90,000 g/mol to about 180,000 g/mol, or fromabout 100,000 g/mol to about 170,000 g/mol.

Embodiment 11

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer contains an amount of zirconium in any range disclosedherein, e.g., from about 10 ppb to about 150 ppb, from about 20 ppb toabout 80 ppb, from about 30 ppb to about 75 ppb, or from about 25 ppb toabout 60 ppb.

Embodiment 12

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer contains substantially no peroxide residue or peroxidedecomposition by-products.

Embodiment 13

The homopolymer defined in any one of the preceding embodiments, whereinthe homopolymer is a single reactor product, e.g., not a post-reactorblend of two polymers, for instance, having different molecular weightcharacteristics.

Embodiment 14

An article comprising the homopolymer defined in any one of embodiments1-13.

Embodiment 15

An article comprising the homopolymer defined in any one of embodiments1-13 and an additive.

Embodiment 16

The article defined in embodiment 14 or 15, wherein the article is amolded product, a nonwoven article, or a fiber or fabric.

Embodiment 17

A fiber or fabric or nonwoven article comprising the homopolymer definedin any one of embodiments 1-13.

Embodiment 18

A fiber or fabric or nonwoven article comprising the homopolymer definedin any one of embodiments 1-13 and an additive.

Embodiment 19

The article or fiber or fabric defined in any one of embodiments 15-16or 18, wherein the additive comprises an antioxidant, acid scavenger,antiblock additive, slip additive, colorant, filler, processing aid, UVinhibitor, or any combination thereof.

Embodiment 20

A method of making a fiber (e.g., meltblown or spunbond) comprising apolypropylene homopolymer, the method comprising:

(i) providing a polypropylene homopolymer defined in any one ofembodiments 1-13; and

(ii) melt processing the polypropylene homopolymer through a fiber dieto form the fiber.

Embodiment 21

The method defined in embodiment 20, wherein the method comprises meltprocessing the homopolymer and at least one additive through the die.

Embodiment 22

The method defined in embodiment 21, wherein the additive comprises anantioxidant, acid scavenger, antiblock additive, slip additive,colorant, filler, processing aid, UV inhibitor, or any combinationthereof.

Embodiment 23

A fiber formed by the method defined in any one of embodiments 20-22.

Embodiment 24

The fiber or method defined in any one of embodiments 17-23, wherein thefiber has a diameter/thickness in any range disclosed herein, e.g., fromabout 0.1 microns to about 20 microns, from about 0.5 microns to about15 microns, from about 1 micron to about 12 microns, or from about 2microns to about 10 microns.

Embodiment 25

A catalyst composition comprising any racemicansa-bis(indenyl)zirconocene compound disclosed herein, anyactivator-support disclosed herein, and optionally, any co-catalystdisclosed herein.

Embodiment 26

The composition defined in embodiment 25, wherein the metallocenecompound comprises a silicon, carbon, or germanium bridging atom.

Embodiment 27

The composition defined in embodiment 25 or 26, wherein the indenylgroups are substituted indenyl groups, e.g., with any suitablesubstituent, any suitable number of substituents, and any suitableposition that conforms to rules of chemical valence.

Embodiment 28

The composition defined in any one of embodiments 25-27, wherein theindenyl groups have a phenyl or substituted phenyl substituent.

Embodiment 29

The composition defined in any one of embodiments 25-28, wherein themetallocene compound comprises an alkenyl substituent, e.g., on theindenyl groups or as part of the bridging group.

Embodiment 30

The composition defined in embodiment 25, wherein the metallocenecompound has formula (A):

rac-E(InR_(n))₂ZrX₂  (A);

wherein In is an indenyl group, each X independently is any monoanionicligand disclosed herein, each R independently is any substituentdisclosed herein, n is any integer from 0 to 6 (inclusive), and E is anybridging group disclosed herein.

Embodiment 31

The composition defined in embodiment 30, wherein E is a bridging groupof the formula >E^(A)R¹R², wherein E^(A) is a carbon, silicon, orgermanium atom, and R¹ and R² independently are any substituentdisclosed herein, e.g., H, a halide, a C₁ to C₃₆ hydrocarbyl group, a C₁to C₃₆ halogenated hydrocarbyl group, a C₁ to C₃₆ hydrocarboxy group, ora C₁ to C₃₆ hydrocarbylsilyl group; or H or a hydrocarbyl group havingup to 18 carbon atoms.

Embodiment 32

The composition defined in embodiment 31, wherein at least one of R¹ andR² is a phenyl group.

Embodiment 33

The composition defined in embodiment 31, wherein at least one of R¹ andR² is an alkyl group (e.g., a C₁ to C₈ alkyl group).

Embodiment 34

The composition defined in embodiment 31, wherein at least one of R¹ andR² is an alkenyl group (e.g., a C₃ to C₈ terminal alkenyl group).

Embodiment 35

The composition defined in any one of embodiments 30-34, wherein each Rindependently is any substituent disclosed herein, e.g., H, a halide, aC₁ to C₃₆ hydrocarbyl group, a C₁ to C₃₆ halogenated hydrocarbyl group,a C₁ to C₃₆ hydrocarboxy group, or a C₁ to C₃₆ hydrocarbylsilyl group;or H or a hydrocarbyl group having up to 18 carbon atoms.

Embodiment 36

The composition defined in any one of embodiments 30-35, wherein n isequal to 1 or 2.

Embodiment 37

The composition defined in any one of embodiments 30-35, wherein n isequal to 0.

Embodiment 38

The composition defined in any one of embodiments 30-35, wherein n isequal to 2, and one R is an alkyl or alkenyl group, and the other R is aphenyl or alkyl-substituted phenyl group.

Embodiment 39

The composition defined in any one of embodiments 30-38, wherein each Xindependently is H, BH₄, a halide, a C₁ to C₃₆ hydrocarbyl group, a C₁to C₃₆ hydrocarboxy group, a C₁ to C₃₆ hydrocarbylaminyl group, a C₁ toC₃₆ hydrocarbylsilyl group, a C₁ to C₃₆ hydrocarbylaminylsilyl group,OBR^(Z) ₂, or OSO₂R^(Z), wherein R^(Z) is a C₁ to C₃₆ hydrocarbyl group.

Embodiment 40

The composition defined in any one of embodiments 30-38, wherein each Xindependently is any halide or C₁ to C₁₈ hydrocarbyl group disclosedherein.

Embodiment 41

The composition defined in any one of embodiments 30-38, wherein each Xis Cl.

Embodiment 42

The composition defined in any one of embodiments 25-41, wherein theactivator-support comprises any solid oxide treated with anyelectron-withdrawing anion disclosed herein.

Embodiment 43

The composition defined in any one of embodiments 25-41, wherein theactivator-support comprises fluorided alumina, chlorided alumina,bromided alumina, sulfated alumina, fluorided silica-alumina, chloridedsilica-alumina, bromided silica-alumina, sulfated silica-alumina,fluorided silica-zirconia, chlorided silica-zirconia, bromidedsilica-zirconia, sulfated silica-zirconia, fluorided silica-titania,fluorided silica-coated alumina, fluorided-chlorided silica-coatedalumina, sulfated silica-coated alumina, phosphated silica-coatedalumina, or any combination thereof.

Embodiment 44

The composition defined in any one of embodiments 25-41, wherein theactivator-support comprises fluorided alumina, sulfated alumina,fluorided silica-alumina, sulfated silica-alumina, fluoridedsilica-coated alumina, fluorided-chlorided silica-coated alumina,sulfated silica-coated alumina, or any combination thereof.

Embodiment 45

The composition defined in any one of embodiments 25-41, wherein theactivator-support comprises a fluorided solid oxide, a sulfated solidoxide, or a combination thereof.

Embodiment 46

The composition defined in any one of embodiments 25-45, wherein theactivator-support further comprises any metal or metal ion disclosedherein, e.g., zinc, nickel, vanadium, titanium, silver, copper, gallium,tin, tungsten, molybdenum, zirconium, or any combination thereof.

Embodiment 47

The composition defined in any one of embodiments 25-46, wherein thecatalyst composition comprises a co-catalyst, e.g., any co-catalystdisclosed herein.

Embodiment 48

The composition defined in any one of embodiments 25-47, wherein theco-catalyst comprises any organoaluminum compound disclosed herein.

Embodiment 49

The composition defined in embodiment 48, wherein the organoaluminumcompound comprises trimethylaluminum, triethylaluminum,triisobutylaluminum, or a combination thereof.

Embodiment 50

The composition defined in any one of embodiments 25-49, wherein thecatalyst composition is substantially free of aluminoxane compounds,organoboron or organoborate compounds, ionizing ionic compounds, orcombinations thereof.

Embodiment 51

The composition defined in any one of embodiments 25-50, wherein thecatalyst composition is produced by a process comprising contacting, inany order, the metallocene compound, the activator-support, and theco-catalyst.

Embodiment 52

The composition defined in any one of embodiments 25-51, wherein acatalyst activity (or a catalyst productivity) of the catalystcomposition is in any range disclosed herein, e.g., at least about 1,000grams, at least about 2,000 grams, at least about 3,500 grams, or atleast about 5,000 grams, and often up to about 10,000 grams, up to about15,000 grams, up to about 20,000 grams, or up to about 25,000 grams ofpolypropylene homopolymer per gram of activator-support per hour (orgrams of polypropylene homopolymer per gram of activator-support), underbulk polymerization conditions, with a triisobutylaluminum co-catalyst,a polymerization temperature of 77° C. and a reactor pressure of 520psig (3.58 MPa).

Embodiment 53

The composition defined in any one of embodiments 25-52, wherein acatalyst activity (or a catalyst productivity) of the catalystcomposition is in any range disclosed herein, e.g., at least about250,000 grams, at least about 500,000 grams, at least about 1,000,000grams, or at least about 1,500,000 grams, and often up to about2,000,000 grams, up to about 3,000,000 grams, up to about 4,000,000grams, or up to about 5,000,000 grams of polypropylene homopolymer pergram of metallocene compound per hour (or grams of polypropylenehomopolymer per gram of metallocene compound), under bulk polymerizationconditions, with a triisobutylaluminum co-catalyst, a polymerizationtemperature of 77° C. and a reactor pressure of 520 psig (3.58 MPa).

Embodiment 54

The composition defined in any one of embodiments 25-53, wherein themetallocene compound comprises an alkenyl substituent, and a catalystactivity (or a catalyst productivity) of the catalyst composition isgreater than that of a catalyst composition containing a similarmetallocene compound without the alkenyl substituent, under the samepolymerization conditions (bulk polymerization conditions, with atriisobutylaluminum co-catalyst, 600 molar ppm of H₂, a polymerizationtemperature of 77° C. and a reactor pressure of 520 psig (3.58 MPa)) andusing the same catalyst preparation conditions and catalyst components(other than the metallocene compound).

Embodiment 55

A polymerization process, the process comprising contacting the catalystcomposition defined in any one of embodiments 25-54 with propylene in apolymerization reactor system under polymerization conditions to producea polypropylene homopolymer.

Embodiment 56

The process defined in embodiment 55, wherein the polymerization reactorsystem comprises a batch reactor, a slurry reactor, a gas-phase reactor,a solution reactor, a high pressure reactor, a tubular reactor, anautoclave reactor, or a combination thereof.

Embodiment 57

The process defined in embodiment 55, wherein the polymerization reactorsystem comprises a slurry reactor, a gas-phase reactor, a solutionreactor, or a combination thereof.

Embodiment 58

The process defined in embodiment 55, wherein the polymerization reactorsystem comprises a loop slurry reactor.

Embodiment 59

The process defined in any one of embodiments 55-58, wherein thepolymerization reactor system comprises a single reactor.

Embodiment 60

The process defined in any one of embodiments 55-58, wherein thepolymerization reactor system comprises 2 reactors.

Embodiment 61

The process defined in any one of embodiments 55-58, wherein thepolymerization reactor system comprises more than 2 reactors.

Embodiment 62

The process defined in any one of embodiments 55-61, wherein thepolymerization conditions comprise a polymerization reaction temperaturein a range from about 25° C. to about 175° C. and a reaction pressure ina range from about 200 psig to about 1000 psig (about 1.4 MPa to about6.9 MPa).

Embodiment 63

The process defined in any one of embodiments 55-62, wherein thepolymerization conditions are substantially constant, e.g., for aparticular polymer grade.

Embodiment 64

The process defined in any one of embodiments 55-63, wherein no hydrogenis added to the polymerization reactor system.

Embodiment 65

The process defined in any one of embodiments 55-63, wherein hydrogen isadded to the polymerization reactor system.

Embodiment 66

The process defined in embodiment 65, wherein the MFR of thepolypropylene homopolymer increases by from about 200% to about 1000%,based on an increase in molar H₂ concentration (based on propylene) from600 ppm to 1100 ppm.

Embodiment 67

The process defined in embodiment 65 or 66, wherein the ratio of Mw/Mnis substantially constant (e.g., within +/−25%) over a range of from 600ppm to 1000 molar ppm H₂, i.e., a flat or substantially constant Mw/Mnwith increasing hydrogen concentration.

Embodiment 68

The process defined in any one of embodiments 65-67, wherein themetallocene compound comprises an alkenyl substituent, and the Mw/Mn ofthe polypropylene homopolymer produced by the process is less than thatof a homopolymer obtained using a similar metallocene compound withoutthe alkenyl substituent, under the same polymerization conditions, usingthe same catalyst preparation conditions and catalyst components (otherthan the metallocene compound).

Embodiment 69

The process defined in any one of embodiments 65-68, wherein the processis conducted in the presence of a molar amount of H₂, based onpropylene, in any range disclosed herein, e.g., from about 200 ppm toabout 2000 ppm, or from about 300 ppm to about 1500 ppm H₂.

Embodiment 70

The process defined in any one of embodiments 55-69, wherein the processdoes not include a vis-breaking step.

Embodiment 71

The process defined in any one of embodiments 55-70, wherein thepolypropylene homopolymer produced is defined in any one of embodiments1-13.

Embodiment 72

A polypropylene homopolymer produced by the process defined in any oneof embodiments 55-70.

Embodiment 73

A polypropylene homopolymer defined in any one of embodiments 1-13produced by the process defined in any one of embodiments 55-70.

Embodiment 74

An article (e.g., a fiber) comprising the homopolymer defined in any oneof embodiments 72-73.

We claim:
 1. A polypropylene homopolymer having a melt flow rate in arange from about 200 g/10 min to about 3000 g/10 min, a ratio of Mw/Mnin a range from about 2 to about 5, and a peak melting point in a rangefrom about 138° C. to about 151° C.
 2. A fiber or fabric comprising thepolypropylene homopolymer of claim
 1. 3. The homopolymer of claim 1,wherein the polypropylene homopolymer is further characterized by aratio of Mz/Mw in a range from about 1.7 to about 3.5.
 4. Thehomopolymer of claim 1, wherein: the melt flow rate is in a range fromabout 500 g/10 min to about 2500 g/10 min; the ratio of Mw/Mn is in arange from about 2.2 to about 4.5; and the peak melting point is in arange from about 140° C. to about 150° C.
 5. The homopolymer of claim 4,wherein the polypropylene homopolymer is further characterized by aratio of Mz/Mw in a range from about 1.9 to about 2.8.
 6. Thehomopolymer of claim 1, wherein the polypropylene homopolymer is furthercharacterized by an isotacticity [mm] in a range from about 93% to about99%.
 7. The homopolymer of claim 1, wherein the polypropylenehomopolymer is further characterized by: a Mw in a range from about40,000 g/mol to about 110,000 g/mol; a Mn in a range from about 10,000g/mol to about 40,000 g/mol; a Mz in a range from about 80,000 g/mol toabout 230,000 g/mol; or any combination thereof.
 8. The homopolymer ofclaim 1, wherein the polypropylene homopolymer contains from about 10parts per billion by weight of zirconium to about 150 parts per billionby weight of zirconium.
 9. A method of making a fiber, the methodcomprising melt processing the polypropylene homopolymer of claim 1through a fiber die to form the fiber.
 10. The method of claim 9,wherein the fiber has a diameter in a range from about 0.5 microns toabout 15 microns.
 11. A polymerization process, the process comprisingcontacting a catalyst composition with propylene in a polymerizationreactor system under polymerization conditions to produce apolypropylene homopolymer, wherein the catalyst composition comprises aracemic ansa-bis(indenyl)zirconocene compound, an activator-support, andan optional co-catalyst.
 12. The process of claim 11, wherein thepolymerization reactor system comprises a slurry reactor, gas-phasereactor, solution reactor, or a combination thereof.
 13. The process ofclaim 11, wherein: the polymerization reactor system comprises a loopslurry reactor; and the catalyst composition comprises an organoaluminumco-catalyst.
 14. The process of claim 11, wherein: a melt flow rate ofthe polypropylene homopolymer increases by from about 200% to about1000%, based on an increase in molar H₂ concentration, based onpropylene, from 600 ppm to 1100 ppm; or a ratio of Mw/Mn of thepolypropylene homopolymer is substantially constant over a range of from600 molar ppm H₂ to 1000 molar ppm H₂, based on propylene; or both. 15.The process of claim 11, wherein the metallocene compound comprises analkenyl substituent, and a ratio of Mw/Mn of the polypropylenehomopolymer produced by the process is less than that of a homopolymerobtained using a similar metallocene compound without the alkenylsubstituent, under the same catalyst preparation and polymerizationconditions.
 16. A catalyst composition comprising: a racemicansa-bis(indenyl)zirconocene compound; an activator-support; andoptionally, a co-catalyst.
 17. The composition of claim 16, wherein themetallocene compound has formula (A):rac-E(InR_(n))₂ZrX₂  (A); wherein: In is an indenyl group; each Xindependently is a monoanionic ligand; each R independently is H, ahalide, a C₁ to C₃₆ hydrocarbyl group, a C₁ to C₃₆ halogenatedhydrocarbyl group, a C₁ to C₃₆ hydrocarboxy group, or a C₁ to C₃₆hydrocarbylsilyl group; n is an integer from 0 to 6, inclusive; and E isa bridging group of the formula >E^(A)R¹R², wherein E^(A) is a carbon,silicon, or germanium atom, and R¹ and R² independently are H, a halide,a C₁ to C₃₆ hydrocarbyl group, a C₁ to C₃₆ halogenated hydrocarbylgroup, a C₁ to C₃₆ hydrocarboxy group, or a C₁ to C₃₆ hydrocarbylsilylgroup.
 18. The composition of claim 17, wherein: each X independently isa halide or C₁ to C₁₈ hydrocarbyl group; each R independently is H or aC₁ to C₁₈ hydrocarbyl group; n is equal to 0, 1, or 2; E^(A) is a carbonor silicon atom; R¹ and R² independently are a phenyl group, a C₁ to C₈alkyl group, or a C₃ to C₈ terminal alkenyl group; the activator-supportcomprises a fluorided solid oxide, a sulfated solid oxide, or acombination thereof; and the catalyst composition comprises anorganoaluminum co-catalyst.
 19. The composition of claim 16, wherein: acatalyst activity of the catalyst composition is at least about 2,000grams of polypropylene homopolymer per gram of activator-support perhour, under bulk polymerization conditions, with a triisobutylaluminumco-catalyst, a polymerization temperature of 77° C. and a reactorpressure of 520 psig (3.58 MPa); a catalyst activity of the catalystcomposition is at least about 1,000,000 grams of polypropylenehomopolymer per gram of metallocene compound per hour, under bulkpolymerization conditions, with a triisobutylaluminum co-catalyst, apolymerization temperature of 77° C. and a reactor pressure of 520 psig(3.58 MPa); or both.
 20. The composition of claim 16, wherein themetallocene compound comprises an alkenyl substituent, and a catalystactivity of the catalyst composition is at least 10% greater than thatof a catalyst composition containing a similar metallocene compoundwithout the alkenyl substituent, under bulk polymerization conditions,with a triisobutylaluminum co-catalyst, 600 molar ppm of H₂, apolymerization temperature of 77° C. and a reactor pressure of 520 psig(3.58 MPa).